Powerhorse M166113F.2 Owner'S Manual Download Page 47 | Manualshive

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166113 Engine Parts Rev – G

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Summary of Contents for M166113F.2

Page 1: ...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 Fire Explosion DO NOT overload generator per rated capacity and OPERATE ONLY in an a...

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

Page 3: ...UP Power Source 15 4 Selecting a Suitable Site 18 5 Grounding the Generator 20 Operation 1 General Safety Rules for Operation 21 2 Preparing for Operation 24 3 Starting the Engine 27 4 Checking Generator Output 28 5 Connecting Loads 29 6 Stopping the Engine 29 7 Storage Exercise 30 Maintenance Repair 32 Troubleshooting 34 Summary of Important Safety Information for Operation 35 Engine Operation 39...

Page 4: ...vide 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 requi...

Page 5: ...etermine 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 and have it on hand when you call in on a warranty claim or replacement parts ATTENTION All Rental Companies and Priva...

Page 6: ...n 5 Engine 420cc Engine Speed 3750 RPM Fuel Type Unleaded gasoline Fuel Capacity 6 6 gallons 25 L Oil Capacity 1 05 US quarts 1 0 L Starting Method Recoil 120 240 V Receptacles 4 20 Amp A duplex NEMA 5 20R 1 30 Amp 120 240V locking NEMA L14 30R Circuit Breakers 1 8 Amp A thermal push to reset 4 20 Amp A thermal push to reset 2 23 Amp A thermal push to reset Dimensions Length 28 cm Width 20 cm Heig...

Page 7: ...Safety Label Locations 7 Part 782926 Part 782925 Part 782929 Part 782636 Part 782628 Part 782412 Part 782554 Part 782933 Part 782629 Part 782416 1 of 2 ...

Page 8: ...Safety Labels Locations 8 Part 782633 Part 782932 Part 782630 1 of 2 Part 782416 2 of 2 Part 782630 2 of 2 ...

Page 9: ...ke 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: ... Breaker 3 Recoil 13 12VDC Supply 4 Handle 14 Voltmeter 5 Air Cleaner 15 Circuit Breaker 6 Gas Cap 16 120V 20A Duplex Receptacle 7 6 6 Gallon Gas Tank 17 Circuit Breaker 8 Generator Head 18 120 240V 30A Locking Receptacle 9 Muffler 19 Grounding Post 10 Low Oil Warning 20 Fuel Shut Off 10 12 11 13 14 15 17 18 8 9 19 9 2 1 7 3 6 4 2 6 20 5 16 ...

Page 11: ...rning Lamp turns on if oil is low Reference 11 Engine Switch On Off for power to engine for starting Reference 12 Circuit Breaker Circuit breakers protect against electrical overloads Reference 13 12VDC Supply 12 volts for charging battery and operating other 12 volt devices Reference 14 Voltmeter Voltmeter needle should be in appropriate voltage range during all generator load conditions Referenc...

Page 12: ...ate 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 Esti...

Page 13: ...ng 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 c...

Page 14: ...on electric start models only 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 If you have damaged components...

Page 15: ...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 approved transfer switch installed by a...

Page 16: ...lug electric devices and appliances directly into the generator s electrical outlets There are two different kinds of electrical outlets on the generator 1 Four 120 Volt 20 Amp duplex straight blade receptacles NEMA 5 20R duplex receptacles compatible with NEMA 5 20P or 5 15P mating plugs 2 One 120 240 Volt 30 Amp Locking receptacle NEMA L14 30R compatible with NEMA L14 30P mating plugs See more t...

Page 17: ...10 Ga Cord 12 Ga Cord 14 Ga Cord 16 Ga Cord 10 2400 250 150 100 75 20 4800 125 75 50 25 30 7200 60 35 25 10 40 9600 30 15 10 50 12000 15 WARNING Use of under sized extension cords can cause electric shock fire or damage to connected devices All extension and appliance cords must be in good condition and not worn bare frayed or otherwise damaged WARNING Use of damaged electric cords can cause elect...

Page 18: ... choose to operate the generator must be OUTDOORS and away from all air intakes Never run the generator inside any closed or semi enclosed spaces even if outdoors including homes garages basements sheds or boxes These spaces can trap poisonous gases even if you run a fan or open windows Place the generator so that the exhaust fumes will not be directed towards people or building air intakes Ensure...

Page 19: ...n cause combustible materials to catch on fire Make sure your generator s exhaust system is at least 7 feet from all combustible materials and buildings structures Equip the engine with a spark arrestor if the generator will be used near any ignitable forest brush or grassy land See the Specifications section of this manual to determine if your generator is already equipped Make sure you comply wi...

Page 20: ...a 10 gauge wire from the clamp to the generator grounding post located on the rear of the generator head 4 Do not connect the generator grounding post to a water pipe or a ground used by a radio system If a licensed electrician installs the generator with a connection to your building s electrical circuit for use as a back up power system grounding may alternatively be completed through the buildi...

Page 21: ... 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 other purposes as unforeseen hazards or equipment damage may result Under the influence Never operate or let anyone else operate the generator while under the influence of alcohol drugs or medication Safety equipment controls...

Page 22: ...e of California to cause cancer birth defects or other 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 the rain or snow Electric shock may result Ground fault circuit interrupter Always use a ground fault circuit interrupter GFCI protected extension co...

Page 23: ...retain 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 fuel tank container can reach as high as several thousand volts A static electric spark can be generated if the static electric charge stored on an object jumps to another less charged object Such a sp...

Page 24: ... sure that any regular maintenance has been performed as prescribed in this manual in the Maintenance Repair section 1 Refer to the engine owner s manual for engine maintenance instructions 2 Make sure battery is charged Charge as needed according to your battery manufacturer s instructions Check add oil Check the oil level using the dipstick and add oil as needed Using a funnel add oil up to the ...

Page 25: ...fore removing gas cap Note A running or still hot engine is hot enough to ignite fuel 3 Remove generator gasoline cap 4 Add gasoline through the fill opening Use only a UL approved portable gasoline container to transfer the gasoline to the generator s tank Follow the safety warning and instructions below for avoiding static electric sparking Do NOT overfill the gasoline tank Allow at least 1 2 in...

Page 26: ...re starting engine 7 Store extra gasoline in a cool dry place in an UL approved tightly sealed container IMPORTANT For continuous operation be prepared to check and refuel the engine on a regular basis A tank of gasoline should last about 9 5 hours under 50 load Inspect Fuel System Check for Leaks Inspect fuel system check for leaks BEFORE starting generator Do not start generator until all needed...

Page 27: ...tarter motor ii Release the key when the engine starts b Using recoil start i Turn the engine key switch to the ON position ii Pull the starter grip lightly until you feel resistance then pull the starter cord out briskly and rapidly iii Allow starter cord to return slowly 5 When engine starts move choke lever to RUN position 6 Under long continuous run operating conditions be prepared to a Check ...

Page 28: ...easured voltage should be within the following ranges a 120V 10 at 120V receptacles b 240V 10 at 240V receptacles 4 If measured voltage 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 electrical loads All engines have a tendency to slow down when a load ...

Page 29: ...he recommended sequence is as follows a Connect items with motors such as refrigerators freezers air conditioners or small hand tools one at a time Let each motor stabilize before connecting the next device b Connect any lights you are planning on powering c Connect voltage sensitive equipment such as electronics via surge protectors Plug devices such as TV s computers and microwaves into a UL lis...

Page 30: ...s empty Residual fuel in the tank could ignite o Away from extreme high or low temperatures Note Do not store with battery charger always connected Batteries that are over charged can boil themselves dry and produce excessive amounts of hydrogen an explosive gas Prevent accidental starting Remove key from starter for electric start engines and secure key in a safe location or remove spark plug s i...

Page 31: ...ng fuel stabilizer to the gasoline following manufacturer s instructions Fuel stabilizer steps 1 Ensure gasoline tank is full 2 Add fuel stabilizer to fuel tank 3 Run engine at least 10 minutes after adding stabilizer to allow it to enter the fuel system 4 Shut off engine 5 Disconnect spark plug wire and remove spark plug 6 Add one teaspoon oil through spark plug hole 7 Place rag over spark plug h...

Page 32: ... Replacement parts If a part needs replacement only use factory approved repair parts Replacement parts that do not meet specifications may result in a safety hazard or poor operation of the generator and will void the warranty Perform engine maintenance Perform engine maintenance as specified in the engine owner s manual Engine maintenance items include 1 Changing oil and oil filter 2 Air filter ...

Page 33: ...r clean the generator with a damp cloth or soft bristle brush Do not allow air intakes to become blocked Note Do not spray generator with a garden hose or pressure washer Water may enter the generator and cause damage to the rotor stator or internal windings Recharge and maintain battery if electric start Inspect recharge and maintain your battery according to your battery manufacturer s instructi...

Page 34: ... qualified technician for adjustment Generator overheating a Generator is overloaded b Insufficient ventilation a Reduce the load See Power Load Planning Mgt section of this manual b Make sure there is at least 7 feet of clearance on all sides of generator No output voltage a Defective load connected to generator b Broken or loose wire c Defective receptacle d Defective stator e Defective rotor f ...

Page 35: ...adjusting it must be done by factory authorized personnel Fuel exhaust system Never modify the exhaust system fuel tanks or fuel lines Carbon monoxide poisoning fire or explosion could result Guards Do not operate generator unless all guards and cover shields which prevent access to moving parts and pinch points are in place Failure to guard the power transmission mechanisms may result in serious ...

Page 36: ...and be familiar with its use Safety Before Use Know how to operate Review safety rules Before each use of this generator review the Rules for Safe Operation Failure to follow these rules may result in serious injury or death Know how to operate Be thoroughly familiar with all controls and with the proper use of the equipment Know how to stop the generator quickly if needed Personal protective equi...

Page 37: ... sensitive electronics Some electronic equipment such as computers and audio video equipment can be damaged by small fluctuations in the flow of power Use a surge suppressor for any voltage sensitive electronic equipment you will be powering with the generator Wet conditions Do not operate the generator or handle any electrical equipment while standing in water while barefoot while hands are wet o...

Page 38: ...ercise regularly Exercise generator every four weeks to dry out moisture that accumulates in the windings If generator cannot be exercised on a regular basis prepare generator for long term storage Periodic maintenance Perform periodic maintenance as directed in this manual to keep the generator in safe working condition Safety Inspection Maintenance Inspect and maintain your generator on a regula...

Page 39: ...ure to return the fuel valve to the OFF position after stopping the engine Choke Rod The choke is used to provide an enriched fuel mixture when starting a cold engine It can be opened and closed by operating the choke lever manually Pull the rod out toward CLOSED to enrich the mixture for cold starting Engine Switch Turn the witch ON to run the engine and to stop the engine turn the switch OFF Rec...

Page 40: ...ck the engine with it stopped on a level ground Due to viscosity variances with regions and temperatures select the correct oil using the chart below Engine oil recommended SAE10W 30 Oil Level Check 1 Ensure that the engine is stopped on a level ground 2 Remove the dipstick and clean it 3 Reinsert the dipstick into the oil filler without threading in and check oil level 4 If the oil level is too l...

Page 41: ...ly proficient REGULAR SERVICE PERIOD Before each use Fist month or 20 Hrs Every 3 months or 50 Hrs Every 6 months or 100 Hrs Every year or 300 Hrs Engine oil Check level Change Air filter Check Clean 1 Replace Spark plug Check adjust Replace Spark arres er Clea Idle speed Check adjust 2 Valve clearance Check adjust 2 Combustion chamber Clean After every 500Hrs 2 Fuel tank and filter Clean 2 Fuel t...

Page 42: ...nning b Clean the spark plug with a steel brush If the insulator is damaged replace the spark plug c Measure the spark plug clearance with a feeler The clearance should be 0 7 0 8mm If adjustment is necessary bend the side electrode carefully d Check if the spark plug gasket is in good conditions or replace with a new one Screw on the spark plug to the bottom first by hand and then tighten it up b...

Page 43: ...il and squeeze out the excess oil The engine will smoke during initial startup it too much oil is left in the air cleaner element 4 Reinstall the air cleaner element and the cover Cleaning Sediment The sediment cup prevents dirt or water which may be in the fuel tank from entering the carburetor If the engine has not been run for a long time the sediment cup should be cleaned 1 Turn the fuel valve...

Page 44: ...dust away Removal From Storage Storage time Service item Within one month Use One two months Drain out original fuel of the fuel tank and refuel Two months one year Drain out original fuel of the fuel tank and refuel Drain out fuel in the carburetor Empty the deposit cup Above one year Drain out original fuel of the fuel tank and refuel Empty the fuel cup in the carburetor Empty the deposit cup Mo...

Page 45: ...t spark plug Spark plug faulty fouled or improperly gapped Gap or replace spark plug Spark plug wet with fuel flooded engine Dry and reinstall spark plug Start engine with throttle lever in MAX position 6 Take engine to an authorized servicing dealer or refer to shop manual Fuel filter restricted carburetor malfunction ignition malfunction valves stuck etc Replace or repair fault components as nec...

Page 46: ...octane rating 86 or higher Valve clearance cold engine Intake 0 10 0 02mm Exhaust 0 15 0 02mm Control panel block Engine brake switch Engine block Spark plug Ignition coil Fuel level switch Bl W Bl Bl Bl Model Items Ignition system Transistorized Magneto Spark plug type NHSP LD F7TC Starting Mode Recoil Oil level switch Engine Stop Switch ...

Page 47: ...166113 Engine Parts Rev G 47 ...

Page 48: ...ine 1 40 Clip Fuel Line 1 41 N A Governor Arm 1 42 N A Bolt Governor Arm 1 43 Kit 3 Nut 3 44 N A Crankshaft Assembly 1 Ref Part Description Qty 45 N A Lifter Valve 2 46 N A Packing Case Cover 1 47 N A Balancing Shaft 1 48 N A Camshaft Assembly 1 49 Kit 4 Bolt 5 50 Bolt 2 51 N A Pin Dowel 2 52 N A Gasket Cylinder Head 1 53 N A Bolt 4 54 783127 Spark Plug 1 55 N A Rod Push 2 56 N A Shroud 1 57 Kit 1...

Page 49: ...Kit 1 2 789294 Carburetor Kit 1 3 789287 Air Filter Kit 1 4 790261 Rear Case Cover Kit 1 5 789290 Valve Cover Kit 1 6 789422 Engine Exhaust Kit 1 7 789291 Ignition Coil Kit 1 8 789295 Fuel Line Kit 1 9 783146 Drain Bolt Kit 2 10 787154 Oil Alert Kit 1 11 790381 Governor Spring Kit 1 ...

Page 50: ...166113 Generator Parts Rev G 50 ...

Page 51: ...nel 1 29 1 Kit 12 or 783063 Switch Assembly 1 29 2 Kit 12 or 783058 300V Voltage Meter 1 29 3 Kit 12 or 783059 12V DC Receptacle 1 Ref Part Description Qty 29 4 Kit 12 or 783053 5 20R Duplex Receptacle 4 29 5 Kit 12 or 783050 L14 30R 120 240V Locking Receptacle 1 29 6 789313 Rear Panel Cover 1 29 7 789425 Front Panel Board 1 30 Kit 12 Washer 4 31 Kit 8 Shield Out Muffler 1 32 Side Hood Muffler 1 3...

Page 52: ...ront Iso Mount Bracket Kit 2 5 789303 Rear Iso Mount Bracket Kit 2 6 789306 Automatic Voltage Regulator Kit 1 7 789307 End Cover Kit 1 8 789293 Muffler Shield Kit 1 9 789297 Fuel Cap Kit 1 10 789296 Tank Bolt Grommet Kit 4 11 789298 Tank Assembly 1 12 789314 Control Panel Assembly 1 13 789305 Brush Terminal Block Kit 1 14 789308 Generator Stud Bolt Kit 1 ...

Page 53: ...Wheel Kit Assembly 53 ...

Page 54: ...arts Components not manufactured by Powerhorse are guaranteed by their manufacturer and can be serviced at factory authorized locations near you 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 This warranty spec...

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Page 56: ...56 Distributed by Northern Tool Equipment Co 2800 SouthCross Drive West P O Box 1499 Burnsville MN 55337 0499 ...

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