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Owner's Manual
M166112B
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.
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!
166112
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Table of Contents
Troubleshooting
Related Manuals for Powerhorse M166112B
Summary of Contents for Powerhorse M166112B
- 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...
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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. Planning the Power Load......................14 3. -
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.
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Page 6: Specifications
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... -
Page 7: Safety Label Locations
Safety Label Locations Part # 782554 Part # 782415 Qty 2 Part # 782411 Part # 782635 Part # 782629 Part # 782627 Part # 782631 Part # 782931 Part # 782632 Part # 782628... - Page 8 Safety Labels Locations Part # 782633 Part # 782630 (1 of 2) Part # 782930 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.
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Page 10: Machine Component Identification
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 with Gauge 120V, 20A Duplex Receptacle ? Gallon Gas Tank 120/240V, 30A Locking Receptacle Generator Head Grounding Post 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.
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Page 12: Power Load Planning & Management
Power Load Planning & Management WARNING NEVER exceed the rated wattage capacity of your generator. OVERLOADING may cause SERIOUS DAMAGE to the generator and attached electrical devices, and may result in fire. Your generator MUST BE SIZED PROPERLY to provide both the running and starting (surge) wattage of the devices you will be powering. - Page 13 Power Load Planning & Management (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...
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Page 14: Installation / Initial Set-Up
Installation/Initial & Set-Up 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 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 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 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 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.
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Page 18: Selecting A Suitable Site
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. - Page 19 Installation/Initial Set-Up 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.
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Page 20: Grounding The Generator
Installation/Initial Set-Up 5. Grounding the generator Always ensure the generator is properly grounded to prevent electrical shock. You must always ground the generator by the following method when using the generator as a portable electrical source: 1) Drive a ¾” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth –... -
Page 21: 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 22 Operation 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 23 Operation Static electricity and filling the gasoline tank: Static electricity can initiate from ungrounded gasoline tanks or containers, from flowing gasoline, and from persons carrying a static electric charge Static electricity can explosively ignite gasoline vapors that are present during the fueling process, resulting in serious burns to nearby persons.
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Page 24: Preparing For Operation
Operation 2. Preparing for Operation Position Position generator in accordance with the instructions given in generator “Installation & Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. - Page 25 Operation 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 26 Operation 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.
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Page 27: Starting The Engine
Operation 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 28: Checking Generator Output
Operation 4. Checking Generator Output Although the speed of the engine was carefully adjusted at the factory so that the generator produces the proper voltage and frequency, output voltage should be checked periodically to ensure the generator is working properly before connecting loads to the generator. WARNING: The generator must be run at the correct speed in order to produce the proper electrical voltage and frequency. -
Page 29: Connecting Loads
Operation 5. Connecting Loads You will want to be careful when connecting loads so as not to overload the generator, especially if you are powering devices with motors that require a higher starting power load. Instructions are provided below for connecting loads when you are using the generator: o As a portable power source o Connected to a building as a back-up power source WARNING:... -
Page 30: Storage & Exercise
Operation 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 31 Operation 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...
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Page 32: Maintenance & Repair
GFCI. (Only for (if equipped) those models equipped with GFCI – See the “Specifications” section.) 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... - Page 33 If a part needs replacement, only use parts that meet the manufacturer’s specifications. Replace- ment parts that do not meet specifications may result in a safety hazard or poor operation of the generator. Contact Powerhorse Product Support at 1-866-443-2576 for any questions, problems, or parts orders.
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Page 34: 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 35: 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 36 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 37 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 38 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.
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Page 39: Engine Operation
Engine Troubleshooting 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 40 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 41 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 ○(1) Clean...
- Page 42 Engine Operation (cont’d) Spark Plug Spark Plug Spark plug type: BP6ES, BPR6ES (NGK) or NHSPLD F6RTCU 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 43 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 44 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 45 Engine Operation (cont’d) Note: For the sake of environmental protection, we recommend discarding the old fuel by Removal From filling a closed container and taking it to a local recycling station for disposal. Storage Storage time Service item Within one month Use One-two months Drain out original fuel of the fuel tank and refuel Drain out original fuel of the fuel tank and refuel;...
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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
Engine Specifications Model DJ170F/DJ170N Items Ignition system Non – transistorized ignition (TCI) Spark plug type BRR6ES (NGK), NHSP LD F6RTCU Out direction of power shaft Counterclockwise Spark plug clearance (gap) 0.7-0.8 mm Valve clearance (cold engine) Intake: 0.15±0.02mm; Exhaust: 0.20±0.02mm Oil Capacity 0.65 US qt (0.6 liters) Fuel... -
Page 48: Engine Electrical Diagram
Electrical Diagram... -
Page 49: Exploded Views
166112 Engine Exploded View Rev – B Diag # Part # Description 783104 Rear Case Cover Kit 783136 Dipstick & O-ring Kit 783127 Spark Plug 783126 Drain Bolt kit 783105 Muffler & Shield Kit 783106 Carburetor Kit 783107 Valve Cover Kit 783108 Ignition Coil Kit 783109... - Page 50 166112 Roll Cage/Wheel Kit Exploded View Rev – B Item # Part # Description 783119 Front Isolation Mount & Bracket Kit 783120 Rear Isolation Mount & Bracket Kit 783116 Handle Kit 783121 Handle Restrictor Kit 783137 Frame 783118 Wheel & Axle Kit 783117 Front Leg Support Kit...
- Page 51 166112 Tank Exploded View Rev – B Item # Part # Description 783112 Fuel Valve & Line Kit 783113 Tank Bolt & Grommet Kit 783114 Fuel Cap Kit 783115 Fuel Tank...
- Page 52 166112 Panel Exploded View Rev – B Item # Part # Description 783142 Control Panel Assembly 782394 Back Cover 783063 Engine Switch 783060 Circuit Breaker, 8A 783059 12VDC Outlet 783092 Circuit Breaker, 13.5A 783058 Voltmeter 783053 NEMA 5-20 Receptacle 783050 NEMA L14-30 Receptacle 783095 Low Oil Warning Lamp...
- Page 53 166112 Generator Head Exploded View Rev – B Item # Part # Description 783122 Brush & Terminal Block Kit 783123 Voltage Regulator 783131 Generator Head Bracket 783139 Generator Head 783124 End Cover Kit 783140 Stud Bolt Kit...
- Page 54 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 55 This page has intentionally been left blank...
- Page 56 Distributed by Northern Tool + Equipment Co., 2800 SouthCross Drive West P.O. Box 1499 Burnsville, MN 55337-0499...
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