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Powerhorse 792220, Owner'S Manual

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Powerhorse 792220 Owner'S Manual Download Page 69

Engine Kit Exploded View Rev – G.5 

69 

 

 
 
 
 
 
 
  
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 
 

* Set includes parts for 1 generator

 

Kit # 15 - Crankcase Cover Assembly -  Part # N/A 
Ref # 

Part # 

Description 

Qty 

1 

N/A 

Bolt, Flange M8 x 32 

6 

2 

N/A 

Cover, Crankcase 

1 

3 

N/A 

Plate 

1 

4 

N/A 

Bolt, Flange M6 x 10 

1 

5 

N/A 

Bearing 

1 

7 

N/A 

Pin, Dowel  

2 

6 

*Packing and 

Switch Set  

# 794372 

Packing, Case Cover 

1 

8 

Oil Level Switch 

1 

9 

N/A 

Bolt, Flange M6 x 14 

2 

Summary of Contents for 792220

Page 1: ...oor 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 vi...

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

Page 3: ...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...

Page 4: ...age 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 ca...

Page 5: ...k 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 y...

Page 6: ...600 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...

Page 7: ...horse 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 7908...

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

Page 9: ...scription 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 Re...

Page 10: ...il 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 include...

Page 11: ...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 igniti...

Page 12: ...C 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 posi...

Page 13: ...el 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 6...

Page 14: ...ond 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 Outp...

Page 15: ...er 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...

Page 16: ...tage 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...

Page 17: ...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 Cool...

Page 18: ...attage 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 m...

Page 19: ...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...

Page 20: ...ack 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 transfe...

Page 21: ...ource you can plug electric devices and appliances directly into the generator s electrical outlets There are different kinds of electrical outlets on your generator 1 120 Volt 20 Amp duplex straight...

Page 22: ...e cords must be in good condition and not worn bare frayed or otherwise damaged WARNING Use of damaged electric cords can cause electric shock or fire Note If an extension cord becomes hot to the touc...

Page 23: ...w the directions below for choosing a location to operate your generator in order to avoid carbon monoxide poisoning The location you choose to operate the generator must be OUTDOORS and away from all...

Page 24: ...at least 7 feet from exhaust and allow for adequate clearance above generator so that heat does not build up Hot exhaust clearance The exhaust gas from your generator is extremely hot and can cause c...

Page 25: ...pipe 3 Run a 10 or 8 gauge wire from the clamp to the generator grounding post located on the electrical panel 4 Do not connect the generator grounding post to a water pipe or a ground used by a radio...

Page 26: ...and operation Only trained adults should set up and operate the generator Do not let children operate Intended use Carefully read about and understand the intended use of this generator Do not use for...

Page 27: ...ther reproductive harm Avoid inhalation of exhaust Wet conditions Do not operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet or while in...

Page 28: ...etain static electric charge as can objects made of conductive material e g metal water if they are not electrically grounded The static electric charge on an object such as a human body or plastic fu...

Page 29: ...poisonous gases EVEN if you run a fan or open windows Carbon monoxide exhaust is given off whether you are using gasoline natural gas or propane to power the generator Ground generator Make sure the g...

Page 30: ...fore first use IMPORTANT Under long continuous run operating conditions be prepared to Check engine oil level every time you refuel the generator Change oil after the first 20 operating hours and at l...

Page 31: ...could result in a static electric build up in the generator s tank Always use a portable container to fill the tank See warning box about static electric spark hazards below b Fill gasoline tank OUTD...

Page 32: ...ng 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 read...

Page 33: ...atteries are hazardous because they contain caustic acid can emit explosive gases and can cause electric shock Caution must be exercised when making connections to a battery to avoid shock and contact...

Page 34: ...it is switched on b Fuel is switched on c Choke is switched on B ON warm engine a Ignition circuit is switched on b Fuel is switched on c Choke is switched off NOTE The choke is not required to start...

Page 35: ...ing 6 Under long continuous run operating conditions be prepared to a Check and refuel the engine on a regular basis A tank of gas should last about 11 hours 1 4 load WARNING A running engine is hot e...

Page 36: ...ge is not within the specified range have generator adjusted by factory authorized personnel Do not attempt to adjust the engine speed yourself NOTE Slight variation in voltage speed with changing ele...

Page 37: ...nnecting the items that require the highest wattage first The recommended sequence is as follows a Connect items with motors such as refrigerators freezers air conditioners or small hand tools one at...

Page 38: ...grounded See Installation Initial Set up section o Ensure that the ESC switch is in the same position on both generators o Make sure all devices that were connected to the generator s outlets have be...

Page 39: ...ces 1 Plug an appliance into the 50A receptacles on parallel kit 2 Turn on the appliance Note If either generator is overloaded or if there is a short circuit in a connected appliance the overload ind...

Page 40: ...location or by untrained persons Exercise generator every 4 weeks The generator should be exercised regularly At least every four weeks start the engine and let it run for 10 to 15 minutes with a smal...

Page 41: ...plug 10 Add one teaspoon oil through spark plug hole 11 Place rag over spark plug hole and turn starter or pull the recoil a few times to lubricate the combustion chamber 12 Replace spark plug but do...

Page 42: ...r spark plug wire s before working on the engine or generator to prevent accidental starting Replace guards Make sure all guards and shields are replaced after servicing the generator Repair Major ser...

Page 43: ...evel surface i Fill with the recommend amount and type of engine oil then install and tighten the oil filler cap 4 See Specification section for oil type and capacity NOTE DO NOT tilt generator when a...

Page 44: ...vel surface b Remove the screws 1 and then remove the side cover 2 c Remove the air filter cover and foam element 3 d Wash the foam element in a solution of household detergent and warm water rinse th...

Page 45: ...s 1 and take off the left side cover 2 b Remove spark plug cap 3 Insert the spark plug wrench onto the spark plug 4 Slide the handlebar 5 through the hole in the spark plug wrench 4 and turn it counte...

Page 46: ...the cover screws 1 and the left side cover 2 b Slide the hose clamp 3 downward and pull the fuel hose 4 off of the fuel filter 5 c Remove the fuel filter 5 from the tank fitting 6 d Clean the filter w...

Page 47: ...igns of leaks or deterioration chafed or spongy fuel hose loose connections loose or missing fuel hose clamps damaged gasoline tank or defective gasoline shut off valve Clean inspect spark arrester Cl...

Page 48: ...de 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 k...

Page 49: ...f this manual Voltage too high a Engine speed too high a Bring generator to a qualified technician for adjustment Generator overheating a Generator is overloaded b Insufficient ventilation a Reduce th...

Page 50: ...s and will also void the warranty Engine speed Never attempt to modify the engine speed setting The engine speed is preset for safe and optimal performance of the generator If speed needs adjusting it...

Page 51: ...an 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 p...

Page 52: ...s product contains or emits chemicals known to the State of California to cause cancer birth defects or other reproductive harm Avoid inhalation of exhaust Smoking sparks Never smoke near the running...

Page 53: ...by untrained persons Storage location Store the generator in a dry location away from sources of heat open flames sparks or pilot lights such as water heaters space heaters furnaces clothes dryers or...

Page 54: ...Generator Exploded View Rev G 5 54...

Page 55: ...y 1 Kit 5 Control Panel Assembly 1 2 Control Panel Face 1 3 Kit 3 4 5 7 9 Screw M5 x 12 22 4 Kit 5 30 Amp Twist Lock Receptacle 1 5 20 Amp Duplex Receptacle 2 6 Ground Post Bolt M4 x 6 1 7 Socket Cap...

Page 56: ...bber 1 142 Kit 3 Frame Top Cover 1 143 Pipe Handle 2 144 Bolt Covers 4 145 Gasket Fuel Tank Oil 1 146 Cap Fuel Filler 1 147 Kit 2 Gasket Muffler 1 148 Kit 8 Screw 1 149 5 Kit 18 Air Cleaner bracket 1...

Page 57: ...M6 x 10 4 42 N A Washer 4 43 N A Bolt Flange M6 x 16 4 44 N A Start Rope 1 45 N A Fan Cover 1 152 N A Location Cable Clip 2 153 N A Location Cable Clip 1 Kit 2 Muffler Assembly Part 797321 Ref Part De...

Page 58: ...Generator Kit Exploded View Rev G 5 58...

Page 59: ...Tube Fuel 1 38a N A Tube Fuel 1 38b N A Tube Fuel 1 55 N A Hex Bolt Flange M6 x 20 1 58 N A Hex Bolt Flange M6 x12 9 132 N A Tank Support Left 1 133 N A Tank Support Right 1 134 N A Tank 1 135 N A Bol...

Page 60: ...N A Deactivation Switch 1 12 N A Waterproof Cap Electric Start Switch 1 13 N A Electric Start Switch 1 14 N A DC Receptacle 1 15 N A Rectifier 1 16 795853 Digital Display Meter 1 17 794357 AC Breaker...

Page 61: ...y 1 49 N A Bolt Flange 1 50 N A Flat Washer 1 51 N A Rotor Motor 1 52 N A Bolt Flange M6 x 65 4 53 N A Washer Spring 4 54 N A Motor 1 55 N A Hex Bolt Flange M6 x 20 4 56 794288 Coil Assembly Ignition...

Page 62: ...n 1 93 N A Shock Absorption 1 94 N A Shock Absorption 1 95 N A Shock Absorption 1 96 797561 Ignition 1 97 N A Generator Base 1 98 N A Square Nut 6 99 N A Nut 3 100 N A Wheel Restrictor 1 101 N A Block...

Page 63: ...lf Threading Screw 6 61 N A Muffler Cover 1 62 N A Hex Bolt Flange M5 x 12 6 63 N A Insulation 1 67 N A Insulation 1 68 N A Muffler Cover 1 148 N A Screw 1 Kit 9A Muffler Vent Cover Assembly Part 7943...

Page 64: ...ndow 1 131 N A Screw 1 Kit 10 Left Cover and Case Assembly Part 797660 Ref Part Description Qty 21 N A Screw 2 99 N A Nut 6 114 N A Bolt 3 121 N A Generator Case with hole 1 122 N A Rubber 1 123 N A R...

Page 65: ...rt 794366 Ref Part Description Qty 23 N A Self Threading Screw 6 70 N A Lock Washer 5 99 N A Nut 5 112 N A Generator Case 1 113 N A Rubber 1 114 N A Bolt 3 116 N A Insulation 1 117 N A Insulation 1 11...

Page 66: ...M6 x12 4 62 N A Hex Bolt Flange M5 x 12 3 78 N A Framework 2 79 N A Framework 2 80 N A Start Rope Bracket 1 81 N A Inverter Bracket 1 82 N A Rubber 2 83 794274 Inverter 1 84 N A Rubber 2 85 N A Rubber...

Page 67: ...Filter Head Cover 1 5 N A Gasket Breather Cap 1 6 N A Cap Breather Chamber 1 7 N A Bolt Flange M5 x 10 2 8 N A Shroud 1 9 N A Bolt Flange M6 x 10 2 10 794369 Packing Head Cover 1 11 794370 Spark Plug...

Page 68: ...Kit 14 Crankcase Assembly Part N A Ref Part Description Qty 1 N A Crankcase 1 2 N A Bearing 1 3 N A Oil Seal 1 4 Plug Set 794371 Washer Drain Plug 1 5 Bolt Drain Plug 1 6 Cap Assembly 1 7 72 N A Bott...

Page 69: ...case Cover Assembly Part N A Ref Part Description Qty 1 N A Bolt Flange M8 x 32 6 2 N A Cover Crankcase 1 3 N A Plate 1 4 N A Bolt Flange M6 x 10 1 5 N A Bearing 1 7 N A Pin Dowel 2 6 Packing and Swit...

Page 70: ...Part 794373 Ref Part Description Qty 1 N A Rocker Arm 2 2 N A Valve Rocker Pin 2 3 N A Pin Locker 4 4 N A Push Rod 2 5 N A Lifter Valve 2 6 N A Rotator Valve 2 7 N A Retainer Valve Spring 2 8 N A Spri...

Page 71: ...ty 1 N A Packing Insulator 1 2 N A Insulator Carburetor 1 3 N A Packing Carburetor 1 4 N A Carburetor w Drain Hose 1 5 N A Gasket Carburetor 1 6 N A Bracket Choke 1 7 N A Spacer 1 8 N A Bracket Electr...

Page 72: ...18 Air Filter Assembly Part 794375 Ref Part Description Qty 1 N A Air Cleaner Assembly 1 2 794376 Foam Filter Element 1 3 150 N A Nut Flange M6 2 4 156 N A Bolt Flange M6 x 12 1 5 149 N A Bracket Air...

Page 73: ...paired is the sole decision of 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...

Page 74: ...ARNING This product can expose you to chemicals including gasoline engine exhaust which is known to the State of California to cause cancer and carbon monoxide which is known to the State of Californi...

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