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Owner's Manual
M102222C.1
Instructions for Installation/Set-up, Operation, Servicing, & Storage
Portable, Outdoor Use-Only, Gasoline Generator
102222 – 7,500 Watt Continuous (9,250 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-listed 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-listed 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.
ADD ENGINE OIL: Engine is shipped without oil. See engine section of this manual for instructions on capacity and viscosity
recommendations.
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!
102222
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Summary of Contents for Powerhorse M102222C.1
- Page 1 See the “Installation/Initial Set-Up” section for more information about this requirement. ADD ENGINE OIL: Engine is shipped without oil. See engine section of this manual for instructions on capacity and viscosity recommendations. 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 ......................9 Installation / Initial Set-Up: 1. Unpacking & Delivery Inspection ......................11 2. Planning the Power Load ........................12 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 4 & 5” of this manual. Contact Powerhorse Product Support at 1-866-443-2576 with questions about optional accessories or to order parts. - Page 5 For detailed engine operation and maintenance information, always refer to the engine section of this 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.
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Page 6: Specifications
Specifications Item Number #102222 Maximum Output 9,250 Watts (W) Continuous Output 7,500 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. Run Time at 50% Load 9.6 Hours Engine 420cc Engine Speed 3600 RPM... -
Page 7: Safety Label Locations
Always make sure safety labels are in place and in good condition. If a safety label is missing or not legible, order new labels or unsafe operation could result. To order replacement safety labels, call Powerhorse Product Support at 1-866-443-2576. - Page 8 Safety Label Locations...
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Page 9: Machine Component Identification
Machine Component Identification Reference Reference Reference Description Handle Generator Head Air Filter Control Panel Recoil Starter Grip Battery Location (Battery Not Included) Choke Lever Oil Fill Gas Tank Oil Drain Plug Fuel Gauge Roll Cage Frame Gas Cap Engine Switch Vibration Isolation Mount Fuel Valve Muffler... - Page 10 Machine Component Identification Ref. # Description Qty. 120V, 30A Locking Receptacle (NEMA L5-30R) 120V, 20A GFCI Duplex Receptacle (NEMA 5-20R) Circuit Breaker, 20A Grounding Post 120/240V, 30A Locking Receptacle (NEMA L14-30R) Main Breaker, 30A Multi Meter USB Receptacle with 2 – 5V, 2.1A ports Engine Switch Low Oil Warning Light...
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Page 11: Installation / Initial Set-Up
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. 3. -
Page 12: Planning The Power Load
Installation / Initial Set-Up (cont’d) 2. Planning the Power Load Plan your power load so that you do not exceed the generator’s rated capacity. 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. - Page 13 Installation / Initial Set-Up (cont’d) Running Running Device Watts Device Watts Electric nail gun 1200 Radio Electric range (1 element) 1500 Refrigerator 600 (b) Electric skillet 1250 Slow cooker Furnace fan (1/3 HP) 1200 (a) Submersible pump (1-1/2 HP) 2800 (a) Freezer 800 (b) Submersible pump (1 HP)
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Page 14: Set-Up As A Building Back-Up Or Portable 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 9,000 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-listed transfer switch. - Page 15 Installation / Initial Set-Up (cont’d) Using as a portable When using the generator as a portable power source, you can plug electric power source devices and appliances directly into the generator’s electrical outlets. There are eleven different electrical outlets on the generator: 1.
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Page 16: 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 17 Installation / Initial Set-Up (cont’d) • 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 18: 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 19: 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 20: Wheel Kit Assembly
Installation / Initial Set-Up (cont’d) 7. Wheel Kit Assembly Your generator is equipped with a free wheel kit to provide easy portability. Secure the generator on blocks at least 7” off the ground or work table. Make sure the holes in the base of the generator are not obstructed to allow for installation of axle and vibration brackets. - Page 21 Installation / Initial Set-Up (cont’d) Installing Bushings 1. Insert (4) Bushings into handle. into handle Bushing Handle Installing the handle 2. Attach (1) Handle to (1) Generator Frame. Secure using (2) M8 x 50mm Flange Bolt and (2) M8 Flange Nut. M8 Flange Nut M8 x 50mm Flange Bolt (Flange Bolt A)
- Page 22 Installation / Initial Set-Up (cont’d) Attach Handle Pin to Attach lanyard to pin. Generator Frame Attach lanyard and pin to generator frame by looping the rope around the tube and inserting the pin through the loop. Lanyard...
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Page 23: 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 24 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 25 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.
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Page 26: Preparing For Operation
Operation (cont’d) 2. Preparing for Operation Position Position generator in accordance with the instructions given in “Installation & generator Initial Set-up, Step 4: Select a Suitable Site” of this manual. Operate outside only, on dry, level ground with adequate clearance and ventilation. WARNING: Carbon monoxide poisoning hazard Generators give off carbon monoxide exhaust, a poisonous gas that can kill. - Page 27 Operation (cont’d) Check/fill Check the gasoline level in the generator’s tank using the fuel gauge. If needed, fill gasoline tank tank with fresh UNLEADED gasoline from a portable container, after first reading the warnings and instructions below. WARNING: Gasoline fire/explosion hazard Gasoline is highly flammable and explosive.
- Page 28 Operation (cont’d) WARNING: Static electric spark hazard A static electric spark can explosively ignite gasoline vapor, resulting in a flash fire that could cause serious injury or death. To avoid static electric sparking while filling the gasoline tank, the following steps must be followed to minimize and safely dissipate static electric charge build- up before and during the fueling process: •...
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Page 29: 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 using gasoline: 1) Disconnect all loads to the generator. 2) Turn fuel selector switch to Gasoline. 3) Turn the gasoline fuel line valve to the ON position. -
Page 30: 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 31: Connecting Loads
Operation (cont’d) 5. Connecting Electrical 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: •... -
Page 32: Storage & Exercise
Operation (cont’d) Storage & Exercise When you are finished using the generator, you must: • Disconnect all loads • Shut off fuel supply • Store the generator properly • Plan on exercising the engine regularly unless the generator is prepared for long-term storage Detailed instructions are provided below. -
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 IMPORTANT: If a part needs replacement, only use parts that meet the manufacturer’s specifications. Replacement 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 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) switch installed by a licensed electrician in compliance with all applicable local building and electrical codes. If the generator is not isolated from the utility power system by such means, generator output will back feed into the utility power grid.
- Page 38 Summary of Important Safety Information for Operation (cont’d) Safety – During Use • Safety equipment / controls. Always operate the generator with all safety covers, guards, and barriers in place and in good working order, and all controls properly adjusted for safe operation. •...
- Page 39 Summary of Important Safety Information for Operation (cont’d) 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. • Shut off fuel supply. Make sure gasoline shut-off valve is in the OFF position. •...
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Page 40: Engine Operation
Engine WARNING BEFORE operating the engine, be sure to read this section of the manual, otherwise injury to personnel or damage to equipment may occur. Engine Operation Engine starting 1. Fuel Valve When the fuel valve is in the ON position, fuel is allowed to flow from the fuel tank to the carburetor. Be sure components to return the fuel valve to the OFF position after stopping the engine. - Page 41 Engine (cont’d) Maintenance Before First Every 3 Every 6 Every year schedule REGULAR SERVICE each month months months or 300 Hrs. PERIOD or 20 or 50 or 100 Hrs. Hrs. Hrs. Check level ○ Engine oil Change ○ ○ Check ○...
- Page 42 Engine (cont’d) Oil draining and WARNING: Burn hazard checking oil level Never open oil port while engine is running. Hot oil can spray over face and body. 1. Operate the generator for 3 to 5 minutes to thin oil for easier draining.
- Page 43 Engine (cont’d) Clean air filter WARNING 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 (cont’d) Prepare engine for If you will not be able to exercise the generator regularly, you must prepare the engine long term storage if for long term storage to prevent gum deposits from forming and causing malfunction of the needed engine.
- Page 45 1-866-443-2576 – Powerhorse. Please note, engines with the high-altitude kit installed operated at lower altitudes could cause severe engine damage and affect emissions compliance. When modified, a tag or decal should be added to the product stating that a high-altitude kit was installed and to remind you to re-service the carburetor (re-jet) when operating in lower altitude environments.
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Page 46: Exploded Views
102222 Parts Explosion Rev – C.1... - Page 47 102222 Parts Explosion Rev – C.1 REF# PART # DESCRIPTION REF# PART # DESCRIPTION KIT #15, 803459 GENERATOR HEAD ASSEMBLY 29.9 120V AC 30A L5-30R 803434 KIT #15, KIT #12 GROUNDING POST COMP 29.10 WATERPROOF COVER 803435 KIT #15, KIT #12 CARBON BRUSH COMP 29.11 CIRCUIT BREAKER 20A...
- Page 48 102222 Parts Explosion Rev – C.1 Kit #1 Kit #2 Kit #3 Kit #4 Kit #7 Kit #8 Kit #5 Kit #6 Kit #11 Kit #9 Kit #10 Kit #15 Kit #14 Kit #12 Kit #13 KIT REF # KIT PART # DESCRIPTION 803460 GROUNDING BOLT KIT...
- Page 49 803385 Engine Parts Explosion Rev – C.1...
- Page 50 803385 Engine Parts Kits Rev – C.1 REF# PART # DESCRIPTION REF# PART # DESCRIPTION Crankcase Lifter, valve Ball bearing Kit #13 Packing, case cover Kit #13 Oil seal Balancing shaft Seal, governor arm shaft Camshaft assembly Kit #12 Shaft, governor arm &...
- Page 51 803385 Engine Parts Explosion Rev – C.1 Kit #1 Kit #2 Kit #3 Kit #4 Kit #5 Kit #7 Kit #6 Kit #8 Kit #9 Kit #10 Kit #13 Kit #11 Kit #12 KIT REF # KIT PART # DESCRIPTION 803387 GOVERNOR AND SPRING KIT 795626...
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Page 52: Warranty
Powerhorse. Powerhorse will not provide for replacement of complete products due to defective parts. 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. - Page 53 This page left intentionally blank...
- Page 54 Distributed by Northern Tool & Equipment Company, Inc. Burnsville, Minnesota 55306 www.northerntool.com Product Made in Vietnam Manual Printed in China...
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