M83169A.3 Item Number: 83169 Serial Number: Owner’s Manual Instructions for Installation/Set-up, Operation, Servicing, & Storage Portable, Outdoor Use-Only, Gasoline Generator 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).
Hazard Signal Word Definitions This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER DANGER indicates a hazardous situation, which if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation, which if not avoided, could result in death or serious injury.
Table of Contents Hazard Signal Word Definitions .................................................................................................... 2 About Your Generator .................................................................................................................... 4 Specifications.................................................................................................................................... 6 Safety Label Locations ................................................
About Your Generator Thank you for purchasing your Powerhorse portable generator! About Your Generator This engine-driven, portable generator is designed to provide up to its rated amount of electrical power. (See specifications section of this manual for model specific ratings) It can supply power: 1. As a portable power source. You can plug appliances directly into the generator’s electrical outlets. 2. As a back-up, standby power source for a building.
About Your Generator Before using, the user shall determine 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 in the back of this manual and have it on hand when you call in on a warranty claim or replacement parts.
Specifications Item Number Maximum Output Continuous Output Voltage Phase Frequency Power Factor Engine Engine Speed Fuel Type Fuel Capacity Oil Type Oil Capacity Noise Level Starting Method Dimensions Length Width Height Dry Weight #83169 2300 Watts (W) 1800 Watts (W) 120 Volt (V) Single phase 60 Hertz (Hz) 1.0 p.f. Powerhorse 80cc 5,400 RPM (with ESC button OFF) Non-leaded automobile gasoline 1.18 US gallons (4.4L) 10W-30 (API Service SE type or higher) 0.42 US quarts (0.35L) 52 dBA @ 7 meters Recoil 20.
Safety Label Locations Ref. No. 1 2 3 4 5 6 7 8 9 N/A N/A N/A Part # 790858 795346 801849 N/A 790908 790852 795127 795126 790856 N/A 801763 801507 Description Overfill & Spark Decal Exhaust Decal Name Plate EPA Decal Oil Fill Decal Burn Hazard Decal CPSC Decal Danger Decal Improper Connection Decal EPA Decal (Attached to engine) Control Panel Decal Powerhorse Decal (front) Qty 1 1 1 1 1 1 1 1 1 1 1 1 Always make sure safety labels are in place and in good condition.
Safety Label Locations 1 2 3 5 4 6 7 8 9 8
Machine Component Identification Ref. 1 2 3 4 5 Ref. 11 12 13 14 15 Description Carrying Handle Recoil Starter Control Panel Fuel Tank Cap Fuel Tank Cap Air Vent Knob Ref. 6 7 8 9 10 Description Ref.
Machine Component Identification REFERENCE GUIDE Reference 1 – Carrying Handle Reference 2 – Recoil Starter Grip Reference 3 – Control Panel Reference 4 – Fuel Tank Cap Reference 5 – Fuel Tank Cap Air Vent Knob Reference 6 – Oil Fill Cover and Port Reference 7 – Spark Plug Maintenance Cover Reference 8 – Muffler Provides a means for moving and lifting the generator. Grasp the handle firmly when pulling the recoil starter grip so the generator does not fall over.
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. Before using your generator, determine the running and starting wattage requirements of all the electrical devices you will be powering simultaneously.
Power Load Planning & Management (cont’d) Device Clothes Dryer (gas) Clothes Washer Coffee Maker Deep Freezer Desktop Computer w/ 17" monitor Dishwasher (Hot Dry) Drill: 1/2in., 5.4 Amps Drill: 3/8in., 4 Amps DVD/CD Player Electric Fence: 25 Miles Electric Fry Pan Electric Range: 8in.
Power Load Planning & Management (cont’d) To calculate the running and starting wattage requirements for the devices you will be powering, follow these steps: 1. Make a list of all electrical devices you will be powering 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.
Installation / Initial Set-Up There are a number of important steps required to set up your generator for initial use. These steps are: 1. 2. 3. 4. 5. Steps for Installation / Initial Set-Up Unpacking & delivery inspection. Planning the power load to stay within the generator’s rated capacity. Setting up generator for the type of power generation you need: a. portable power source, or b. connected to a building as a back-up power source. Selecting a site for using the generator. Grounding.
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 its rated amount 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.
Installation / Initial Set-Up normal line voltage. An unsuspecting utility line worker working on what he thinks is a deactivated line could be electrocuted. If your generator is connected (running or not) when utility power is restored, your generator will be destroyed. It could also explode or cause fire.
Installation / Initial Set-Up WARNING: Use of under sized extension cords can cause electric shock, fire, or damage to connected devices. 3. 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 electric shock or fire. Note: If an extension cord becomes hot to the touch, it is overloaded or damaged and must be replaced.
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. Choose a site that meets all of the criteria specified.
Installation / Initial Set-Up Adequate cooling ventilation The generator needs adequate, unobstructed flow of air to allow for proper cooling of engine and generator head. WARNING: Heat build-up from inadequate ventilation can result in fire, posing a serious risk to nearby persons and structures. • Situate so there is adequate clearance around generator to allow for cooling airflow so that heat does not build up.
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 3/4” or 1” copper pipe or rod into the ground close to the generator. The pipe/rod must penetrate moist earth – the depth required will be dictated by local soil conditions. Consult with an electrician.
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. 1. 2. 3. 4. 5. 6. 7. Operation Procedures General Safety Rules for Operation Preparing for Operation Starting the Engine Checking Generator Output Connecting Electrical Loads (Portable Power Generation) Stopping Storage & Exercise of Generator Each of these procedures is discussed in detail below: 1.
Operation • Malfunction during operation. Immediately turn off the generator if any of the following conditions arise during operation: o o o o o o o o o Excessive change in engine speed, slow or fast Overheating in load connecting devices Sparking or arcs from generator Loss of electrical output Receptacle damage Engine misfire Excessive vibration Flame or smoke Abnormal noise • Adjusting / repairing.
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.
Operation 2. Preparing for Operation Position generator Position generator in accordance with the instructions given in “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. WARNING: Carbon monoxide poisoning hazard Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from air intakes.
Operation 4) Fill with the recommended amount and type of engine oil, then install and tighten the oil filler cap. Max oil level Min oil level 5) Install the oil fill cover 2 and tighten the screw 1. 1 2 (See specification section for oil type and capacity.) WARNING: Burn hazard Never open oil port while engine is running. Hot oil can spray over face and body. ˙ Notes: o Low oil shutdown feature prevents the generator from starting without sufficient oil. o Generator is shipped without oil.
Operation • • • • • gas vapor collection inside enclosures static electric sparks sparks from electric wiring, batteries, or running engines sources of heat (such as a hot engine or exhaust) open flames, including pilot lights 1) Before starting, review the following general safety precautions for fueling: a) Never pump gasoline directly into the generator’s gas tank at a gas station – high velocity flow from the pump could result in a static electric build-up in the generator’s tank.
Operation 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.
Operation • • • • Personal Protection loose connections, loose or missing fuel hose clamps, a damaged gasoline tank, or a defective gasoline shut-off valve. 1) Hearing can be damaged from prolonged, close-range exposure to the type of noise produced by this generator. The use of ear plugs or other hearing protection device is recommended for persons working within 15-20 feet of the running generator for an extended period of time. 2) Loose or dangling apparel can become entangled in moving parts.
Operation 3. Starting the Generator After you have completed the pre-start checklist procedures, you are ready to start the generator. To start the engine: 1) Turn the ESC throttle switch 1 to “MAX”. 1 2) Turn the fuel cap air vent knob to “ON” 2. 2 3) Turn the Engine OFF/RUN/CHOKE control to one of the following: A. CHOKE 3 position for starting a cold engine B. RUN position for starting a warm engine 3 RUN OFF CHOKE NOTE: The choke is not required to start a warm engine.
Operation 4) Pull slowly on the recoil starter until it is engaged, then pull it briskly. NOTE: Grasp the carrying handle firmly to prevent the generator from falling over when pulling the recoil starter. 5) After a cold engine is started, allow time to warm up so when the knob is turned to the RUN position the generator will stay running. 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 8.
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. Output voltage should be checked with a portable voltage meter: 1. Start engine and allow to warm up for five minutes. Do not connect any loads. 2.
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: Do not overload generator. Make sure that combined starting and running loads do not exceed rated capacity of generator.
Operation 2. Disconnect any loads. 3. Turn the Engine OFF/RUN/CHOKE control 2 to “OFF”. a) Ignition circuit and fuel valve is switched off. 2 。。 RUN OFF CHOKE 4. After the engine has completely cooled down, turn the fuel cap air vent knob to “OFF” 3. 7. AC Parallel Operation AC parallel operation allows the connection between two generators to increase available power.
Operation Follow the steps provided below for parallel operation. Connect Parallel 1. Connect the red parallel operation cable to the parallel operation Cables outlets designated with the red o-ring on each of the generators. 2. Connect the black parallel operation cable to the remaining parallel operation outlets on each of the generators. Starting the Generators Connecting Appliances 1. Start both generators and make sure that the output indicator (green) on each generator comes ON. 1.
Operation 8. Storage & Exercise When you are finished using the generator, you must: o Disconnect all loads o Allow generator to completely cool down o Store the generator properly o Plan on exercising the engine regularly unless the generator is prepared for long-term storage. Detailed instructions are provided below.
Operation Prepare engine for 1 to 2 month storage Prepare engine for 2 months to 1 year storage Prepare engine for 1 year or more storage Add fuel stabilizer: 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.
Maintenance & Repair Inspect and maintain your generator as specified below in order to keep it in safe and optimal working order. Follow all safety rules and recommended maintenance steps. WARNING ALWAYS shut off the engine, disconnect the spark plug(s) and discharge the capacitor before cleaning, adjusting, or servicing the generator. Make sure all guards and shields are replaced before using. Note: The generator head is brushless and maintenance free.
Maintenance & Repair (cont’d) c) Remove the oil filler cap 3. d) Place an oil pan under the engine. Tilt the generator to drain the oil completely. e) Place generator on a level surface. f) Fill with the recommend amount and type of engine oil, then install and tighten the oil filler cap (See Specification section for oil type and capacity). NOTE: DO NOT tilt generator when adding engine oil, this could result in overfilling and cause damage to the engine.
Maintenance & Repair (cont’d) Air filter check/replacement a) Place the generator on a level surface and warm up for several minutes. b) Remove the screws 1, and then remove the side cover 2. 1 2 c) Remove the air filter screw 3 and then pull off air filter case cover 4. 3 4 d) Remove the foam element 1 (see image on next page). e) Wash the foam element in a solution of household detergent and warm water, rinse thoroughly and let air dry. f) Soak the foam element in oil and squeeze out excess oil.
Maintenance & Repair (cont’d) Spark plug cleaning and replacement a) Remove the access cover 1 and spark plug cap 2. Insert the spark plug wrench through the access cover opening.
Maintenance & Repair (cont’d) b) Slide the handlebar 3 through the hole in the spark plug wrench 4 and turn it counter clockwise to remove the spark plug. c) Check for discoloration and remove any carbon build up. The porcelain insulator around the center electrode of the spark plug should be a medium-to-light tan color. d) Check the spark plug type and gap a. The gap should be measured with a wire thickness gauge.
Maintenance & Repair (cont’d) Fuel tank filter check/replacement a) Remove the fuel tank cap and filter. b) Clean the filter with gasoline. c) Wipe the filter and install it. d) Install the fuel tank cap.
Maintenance & Repair (cont’d) Fuel filter check/replacement a) Remove the screws 1 and the side cover 2. 1 2 b) Hold and move up the clamp 4, then take off the hose 5 from the bottom of the tank 3. c) d) e) f) g) Remove the fuel filter 6. Clean the filter with gasoline. Dry the filter and put it back into the bottom of the tank. Install the hose and clamp. Install the side cover and tighten the screws.
Maintenance & Repair (cont’d) Draining the Carburetor a) Remove the side cover and screws. b) Loosen the carburetor drain screw. c) Drain fuel into suitable container. d) Tighten the carburetor drain screw. Carburetor Carburetor Drain screw e) Install side cover 2 and tighten the screws 1. 1 2 Check receptacles Check receptacles before each use to make sure they are not cracked or broken. If a receptacle is cracked or otherwise damaged, do not use until replaced with an authorized factory part.
Maintenance & Repair (cont’d) Inspect fuel system / check for leaks Inspect the fuel system and check for leaks on a regular basis. 1) Inspect the entire fuel system. Look for: signs 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.
Maintenance & Repair (cont’d) Keep generator clean High Altitude Operation 4. Install spark arrester. 5. Install the muffler screen and muffler cap. 6. Install the end cover and tighten the screws. Keep generator clean. If dust or debris accumulates on the generator, 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.
Troubleshooting Problem Possible Causes Possible Remedies Engine will not start. a) b) c) d) e) f) a) a) b) c) d) e) f) a) Voltage too low. Low oil level. Fouled spark plug. Out of fuel. Switch in OFF position. Fuel tank cap air vent knob OFF. Bad fuel. Defective invertor board. b) Generator is overloaded. Voltage too high. a) Engine speed too high. Generator overheating. a) Generator is overloaded. b) Insufficient ventilation. No output voltage. a) Defective load connected to generator.
Summary of Important Safety Information for Operation (cont’d) 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.
Summary of Important Safety Information for Operation (cont’d) Safety – Installation & Set-up • Dry, level surface. Situate generator on a dry, firm, level surface. Ensure generator sits level and will not slide or shift during operation. Block wheels if applicable. • Operate OUTSIDE only – dangerous carbon monoxide exhaust! Generators give off carbon monoxide exhaust, a poisonous gas that can kill. You CANNOT smell it, see it, or taste it. ONLY run generator OUTDOORS and away from building air intakes.
Summary of Important Safety Information for Operation (cont’d) • Use approved container. Never pump fuel directly into engine at gas station. Static charge can build and ignite fuel. Use an UL approved fuel container to transfer gas to the engine. • Running / hot engine. A running engine is hot enough to ignite fuel. Never add fuel or remove gas cap if engine is running or still hot. Stop the engine and allow to cool at least two minutes before adding fuel. • Heat / flames / sparks.
Summary of Important Safety Information for Operation (cont’d) • Refueling. DO NOT refuel the engine until it has cooled at least two minutes. • Malfunction during operation.
Generator Parts List – 83169 Rev A.
Generator Parts List – 83169 Rev A.
Generator Parts List – 83169 Rev A.
Engine Parts List – 801795 Rev A.
Engine Parts List – 801795 Rev A.
Engine Parts List – 801795 Rev A.
Limited Warranty Dear Valued Customer: The Powerhorse Product you just purchased is built with the finest material and craftsmanship. Use this product properly and enjoy the benefits from its high performance. By purchasing a Powerhorse product, you show a desire for quality and durability. Like all mechanical equipment this unit requires a due amount of care. Treat this unit like the high quality piece of machinery it is. Neglect and improper handling may impair its performance.
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WARNING: 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 California to cause birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov. Distributed by Northern Tool + Equipment Co., Inc. Burnsville, MN 55306 NorthernTool.
