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Owner's Manual
M166114H
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
166114 - 7250 Watt Continuous (9000 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.
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:
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).
 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.
 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.
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:
SERIAL NUMBER:
_______________
WARNING
CO Poisoning
Electric shock / Electrocution
Fire / Explosion
STOP!
166114

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Summary of Contents for Powerhorse M166114H

  • Page 1 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...
  • Page 2: Hazard Signal Word Definitions

    Hazard Signal Word Definitions...
  • Page 3: Table Of Contents

    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.
  • Page 4: About Your Generator

    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...
  • Page 5 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.
  • Page 6: Specifications

    Specifications Item Number #166114 Maximum Output 9000 Watts (W) Continuous Output 7250 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 420cc Engine Speed 3750 RPM Fuel Type...
  • Page 7: Safety Label Locations

    Safety Label Locations Part # 782554 Part # 782417 (1 of 2) Part # 782413 Part # 782933 Part # 782629 Part # 782925 Part # 782927 Part # 782636 Part # 782929 Part # 782628...
  • Page 8 Safety Label Locations Part # 782417 (2 of 2) Part # 782633 Part # 782630 (1 of 2) Part # 782934 Part # 782630 (2 of 2)
  • Page 9 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.
  • Page 10: Machine Component Identification

    Machine Component Identification Ref. Description Ref. Description Vibration Isolation Mount Circuit Breaker Oil Drain Plug 12VDC Supply Recoil Voltmeter Handle Circuit Breaker Air Cleaner 120V, 20A Duplex Receptacle Gas Cap Circuit Breaker 6.6 Gal. Gas Tank 120V, 30A Locking Receptacle Generator Head Fuel Shut Off Muffler...
  • Page 11 Machine Component Identification REFERENCE GUIDE Reference 1 – Vibration Isolation The engine and generator head are mounted on rubber cylinders Mount that absorb most of the engine vibration. This feature eliminates the tendency of the machine to “walk” which is common in engine- powered equipment.
  • Page 12: Power Load Planning & Management

    Installation / Initial Set-Up 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.
  • Page 13 Installation / Initial Set-Up (cont’d) Running Running Device Watts Device 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...
  • Page 14: Unpacking & Delivery Inspection

    Installation / Initial Set-Up (cont’d) 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.
  • Page 15: Set-Up As A Portable Or Building Back-Up Power Source

    Installation / Initial Set-Up (cont’d) 3. Set-up either as a BUILDING BACK-UP or PORTABLE Power Source This generator is designed to provide up to 9000 watts 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.
  • Page 16 Installation / Initial Set-Up (cont’d) 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.
  • Page 17 Installation / Initial Set-Up (cont’d)  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.
  • Page 18: Selecting A Suitable Site

    Installation / Initial Set-Up (cont’d) 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.
  • Page 19 Installation / Initial Set-Up (cont’d)  Never place the generator immediately adjacent to a building or other structure – allow at least 7 feet clearance.  Do not run the generator in close proximity to other heat-generating equipment, such as another generator. The combined heat that is generated may raise air temperature in the immediate area and there will not be adequate cooling ventilation.
  • Page 20: Grounding The Generator

    Installation / Initial Set-Up (cont’d) 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 ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth –...
  • Page 21: Battery Installation

    Installation / Initial Set-Up (cont’d) 6. Battery Installation Your generator’s engine is equipped with an electric starter which requires the installation of a 12 volt DC battery. See the “Specifications” section of this manual for more specific battery requirements for this generator model, such as minimum amperage or CCA rating.
  • Page 22: Operation

    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. Operation Procedures 1. General Safety Rules for Operation 2. Preparing for Operation 3.
  • Page 23 Operation (cont’d)  Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o Excessive change in engine speed, slow or fast o Overheating in load connecting devices o Sparking or arcs from generator o Loss of electrical output o Receptacle damage o Engine misfire...
  • Page 24 Operation (cont’d) 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.
  • Page 25: Preparing For Operation

    Operation (cont’d) 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation & Initial Set-up, Step 4: Select a Suitable Site” generator of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation.
  • Page 26 Operation (cont’d) WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive. Heat, sparks, and flames can ignite gasoline vapors, which can become widespread during fueling. A flash fire and/or explosion could result and cause serious injury or death. Use extreme care when handling gasoline. Carefully follow all the instructions in this section to avoid the following conditions which could result in gasoline ignition: ...
  • Page 27 Operation (cont’d) ground to be filled.  Keep nozzle in contact with portable container while filling. Manually control the flow of gasoline; do NOT use the nozzle’s lock-open device.  A portable container made of metal or conductive plastic is preferred because it dissipates charge to ground more readily.
  • Page 28: Starting The Engine

    Operation (cont’d) 3. Starting the Engine After you have completed the pre-start checklist procedures, you are ready to start the engine. To start the engine: 1) Disconnect all loads to the generator. 2) Turn the gasoline line valve to the ON position. 3) For cold engine, move choke lever to full choke position.
  • Page 29: Checking Generator Output

    Operation (cont’d) 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. WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency.
  • Page 30: Connecting Loads

    Operation (cont’d) 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:...
  • Page 31: Storage & Exercise

    Operation (cont’d) Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Shut off fuel supply o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage.
  • Page 32 Operation (cont’d) Prepare engine for If you will not be able to exercise the generator regularly, you must long term storage if prepare the engine for long term storage to prevent gum deposits from forming and causing malfunction of the engine. needed Prepare engine for long term storage by: o Removing all gasoline from the tank and carburetor...
  • Page 33: Maintenance & Repair

     Repair. Major service, including the installation or replacement of parts, should be performed only by a qualified electrical service technician. Obtain factory approved parts from Powerhorse Product Support at 1-866-443-2576.  Replacement parts. If a part needs replacement, only use factory approved repair parts.
  • Page 34 To test the GFCI: 1. Depress the TEST button. The RESET button should extend from the receptacle. If the RESET button does not extend, contact Powerhorse for replacement parts. 2. Restore power to the GFCI by firmly pressing the RESET button back into the receptacle until an audible click is heard.
  • Page 35: Troubleshooting

    Troubleshooting TROUBLESHOOTING Problem Possible Causes Possible Remedies Engine will not start. a) Low oil level. a) Fill crankcase to proper oil level. b) Fouled spark plug. b) Clean or replace spark plug. c) Out of fuel. c) Fill fuel tank. d) Engine switch in OFF position.
  • Page 36: Summary Of Important Safety Information For Operation

    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.
  • Page 37 Summary of Important Safety Information for Operation (cont’d) licensed electrician installs the generator with a connection to your building’s electrical circuit for use as a standby power system, grounding will be complete through the building’s grounding system.  Isolate connection to building’s electrical circuit. 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 an UL-approved transfer switch installed by a licensed electrician in compliance with all applicable local building and electrical codes.
  • Page 38 Summary of Important Safety Information for Operation (cont’d)  Inspect fuel system. Check fuel system on a regular basis. Look for signs of leaks, deterioration, chafed or spongy fuel hose, loose or missing fuel hose clamps, damaged fuel tank, or a defective fuel shut-off valve. Do not start generator until needed repairs have been completed.
  • Page 39 Summary of Important Safety Information for Operation (cont’d) Abnormal noise  Adjusting / repairing. Always turn off generator and remove spark plug(s) or spark plug wire(s) before working on the generator to prevent accidental starting. Safety – After use  Cool engine before storing. Let engine cool for at least five minutes before storing. A hot engine can be a fire hazard.
  • Page 40: Engine Operation

    Engine Operation WARNING BEFORE operating the engine, be sure to read this section of the manual, otherwise injury to personnel or damage to equipment may occur. Start Up Instructions Engine Starting Fuel Valve Lever When the valve lever is in the ON position, fuel is allowed to flow from the fuel tank to Devices the carburetor.
  • Page 41 Engine Operation (cont’d) Engine Oil Caution ● Engine oil is a key factor in deciding the engine’s performance. Do not apply engine Recommendations oil with additives or 2-stroke gasoline oil, as they haven’t enough lubrication, which may shorten the engine’s service life. ●...
  • Page 42 Engine Operation (cont’d) Maintenance Schedule REGULAR Before Fist Every Every Every SERVICE PERIOD each month year or 20 months months Hrs. or 50 or 100 Hrs. Hrs. Hrs. · Engine Check ○ level Change ○ ○ · Air filter Check ○...
  • Page 43 Engine Operation (cont’d) Spark Plug Spark Plug Spark plug type: NHSP LD F7TC Removal, Proper spark plug clearance ensures the engine’s normal running under no deposit around the Cleaning and spark plug. Replacement Remove the spark plug by means of spark plug wrench. WARNING Be careful not to touch the muffler during or just after the engine has been running.
  • Page 44 Engine Operation (cont’d) Air Cleaner Never run the generator without the air filter. Rapid engine wear will result. 1. Unsnap the air cleaner cover clips, remove the air cleaner cover, and remove the element. 2. Wash the air cleaner element in a solution of household detergent and warm water, then rinse thoroughly, or wash in nonflammable or high flashpoint solvent.
  • Page 45 Engine Operation (cont’d) Storage 1. Replace engine oil. 2. Disconnect the spark plug. Fill a spoon of fresh engine oil from the spark plug mount hole into the cylinder. Rotate the engine to distribute engine oil evenly, followed by fitting the spark plug to original position. 3.
  • Page 46: Engine Troubleshooting

    Engine Troubleshooting ENGINE WILLNOT Possible Cause Correction START 1. Electric starting Battery discharged. Recharge battery. (applicable types): Fuse burnt out. Replace fuse Check battery and fuse. 2. Check control positions. Fuel valve OFF. Move lever to ON position. Choke open. Move lever to CLOSED position unless the engine is warm.
  • Page 47: Engine Specifications/Electrical Diagram

    Engine Specifications/Electrical Diagram Model Items Ignition system Transistorized Magneto Spark plug type NHSP LD F7TC Starting Mode Recoil/Electric Start Spark plug clearance 0.7-0.8 mm Oil Capacity 1.05 US qt (1.0 liters) Fuel Unleaded gasoline octane rating 86 or higher Valve clearance (cold engine) Intake: 0.10±0.02mm;...
  • Page 48: Exploded Views

    166114 Engine Parts Rev – H...
  • Page 49 166114 Engine Parts Rev – H Ref# Part # Description Ref# Part # Description Crankcase Bolt Kit #4 Ball Bearing Bolt Kit #4 Oil Seal Pin, Dowel Seal, Governor Arm Shaft Gasket, Cylinder Head Shaft, Governor Arm Bolt Washer, Governor Arm Shaft 783127 Spark Plug Pin, Lock...
  • Page 50 166114 Engine Parts Rev – H Kit Ref # Kit Part # Description 789289 Recoil & Fan Kit 789316 Carburetor Kit 789287 Air Filter Kit 790261 Rear Case Cover Kit 789290 Valve Cover Kit 789422 Engine Exhaust Kit 789291 Ignition Coil Kit 789295 Fuel Line Kit 783146...
  • Page 51 166114 Generator Parts Rev – H...
  • Page 52 166114 Generator Parts Rev – H Ref# Part # Description Ref# Part # Description 789319 Generator Head Assy. 783050 L14-30R, 120/240V-30A 29.5 789320 Rotor Locking Receptacle Kit #13 789321 Stator 789313 Carbon Brush Kit #14 29.6 Rear Panel Cover Terminal Block Kit #13 783172 Generator Bracket...
  • Page 53 166114 Generator Kits Rev – H Kit #2 Kit #3 Kit #1 Kit #4 Kit Ref # Kit Part # Description 789299 Handle Kit 789454 Front Leg Support Kit 789301 Wheel & Axle Kit 789322 Battery Cable Kit 789302 Front Iso Mount & Bracket Kit 789303 Rear Iso Mount &...
  • Page 54 Wheel Kit Assembly...
  • Page 55: Warranty

    Any costs incurred due to replacement or repair of items outside of a Powerhorse approved facility is the responsibility of the buyer and not covered under warranty. Powerhorse can supply you with the service center location in your area.
  • Page 56 Distributed by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...

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