Powerhouse PH2100PRi Shop Manual
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Powerhouse PH2100PRi Shop Manual

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POWERHOUSE
®
POWERHOUSE POWER PRODUCTS
PH2100PRi SHOP MANUAL
Coast Distribution
April, 2011
1
PH2100PRI SM 04-27-2011

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  • Page 1 POWERHOUSE ® POWERHOUSE POWER PRODUCTS PH2100PRi SHOP MANUAL Coast Distribution April, 2011 PH2100PRI SM 04-27-2011...

  • Page 2: Preface

    Preface This manual covers the construction, function and servicing procedure of the POWERHOUSE® PH2100PRi generator, certificated by CARB. Careful observance of these instructions will result in better, safe service work. All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing.

  • Page 3: Table Of Contents

    5 Muffler system ............................40 6. Carburetor .............................. 43 7. Control panel ............................48 8. Outer generator housing ........................49 9. Recoil starter / Electric Starter / Ignition coil ..................50 10. Rotor/Stator disassembly / reassembly ....................55 PH2100PRI SM 04-27-2011...
  • Page 4 11. Exploded engine view .......................... 57 12. Valve cover/ Rocker arm ........................60 PH2100PRI SM 04-27-2011...

  • Page 5: Specifications

    Electronic control type Lubrication system Pump Lube oil SAE 15W-40 (SF/SG grade or greater) Oil capacity 15.6 fl oz (460 ml) Starting system Recoil starter / Electric / Remote Stopping system Primary circuit ground Fuel used Automotive unleaded gasoline PH2100PRI SM 04-27-2011...

  • Page 6: Characteristics

    Insulation resistance AC circuit protector DC circuit protector Fuel tank capacity 1.3 gal (4.9L) Continuous running time at Rated load 3.0 ~ 7.5 hours ~ 1/4 load Noise level (Zero load to full load) 56~63 dB (A)/7m PH2100PRI SM 04-27-2011...

  • Page 7: Wiring Diagram

    1.3 Wiring diagram PH2100PRI SM 04-27-2011...

  • Page 8: Service Information

    Gasoline is extremely flammable and explosive under certain conditions. To reduce the possibility of a fire or explosion, use caution when working around gasoline, use only a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away from all fuel-related parts. PH2100PRI SM 04-27-2011...

  • Page 9: Service Rules

    2.3 Service rules 1. Use genuine POWERHOUSE® or POWERHOUSE®-recommended parts and lubricants or their equivalents. Parts that do not meet POWERHOUSE® design specifications may damage the engine. 2. Always install new gaskets, O-rings, etc. when reassembling. 3. When tightening bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified.

  • Page 10: Serial Number Location

    2nd ring 0.15-0.25mm 1.0mm Ring end clearance (0.0059”~0.0098”) (0.039”) 2.0-2.3mm 1.8mm Width t (0.0787”~0.0905”) (0.0590”) 1.85-1.96mm 1.75mm Height h (0.0728”~0.0771”) (0.0688”) 0.03-0.18mm 0.24mm Oil ring Ring side clearance (0.001”~0.007”) (0.009”) 0.20-0.50mm 1.0mm Ring end clearance (0.0078”~0.0196”) (0.039”) PH2100PRI SM 04-27-2011...

  • Page 11: Motor

    Primary side 0.045-0.070Ω Ignition coil Resistance 5-8k Ω — Second side 2.6 Motor Standard(Ω) Part Wire color Item 120V Ω DC winding Resistance blue－blue 0.045~0.070 Ω Sub winding Resistance white－white 0.100~0.160 Ω Main winding Resistance black－black－black 0.250~0.350 PH2100PRI SM 04-27-2011...

  • Page 12: Torque Values

    7.4-8.9 10-12 M12*1.25 51.8-59.2 70-80 Flywheel nut M5 Bolt, nut 3.7~5.2 Standard torque M6 Blot, nut 6~7.4 8-10 M8 Bolt, nut 13.3~16.2 18-22 Note: Use standard torque values for fasteners that are not listed in this table. PH2100PRI SM 04-27-2011...

  • Page 13: Trouble Shooting

    Set in fully close or half close position Carburetor faulty Disassemble and clean Economy switch Inspect Engine speed does not Throttle control motor (step motor) Inspect stabilize, too faulty high or too low Inverter unit faulty Inspect and replace Valve clearance misadjusted Readjust PH2100PRI SM 04-27-2011...

  • Page 14: Difficult Cold Starting

    3.2 Difficult cold starting The choke on the PH2100PRi operates automatically. When the unit is off, the choke will return to the closed position. In some cases, the choke may close too slowly or open too fast. Both conditions can cause difficulty starting the unit.

  • Page 15: Hard Starting

    3. Check for valve cone and base. recoil starter rope several 4. Check for worn piston, piston times. ring or cylinder. Normal compression Install the spark plug securely. Restart the engine according to the starting procedure. PH2100PRI SM 04-27-2011...

  • Page 16: Cylinder Compression Check

    2. Install a compression gauge in the spark plug hole. 3. Put the remote switch is on the OFF position. 4. Turn the ignition switch to the start position and measure the cylinder compression. Cylinder compression 65 psi (0.45Mpa) 800rpm Pressure Gauge Remote Switch PH2100PRI SM 04-27-2011...

  • Page 17: Ignition System

    Set the ignition switch to the “ON” position. Ground the negative (—) electrode (i.e. threaded part) of the spark plug against with a ground wire against the engine block, and pull the recoil starter rope to check the spark plug. Ground Wire Spark Plug Spark Plug Wire PH2100PRI SM 04-27-2011...
  • Page 18 Normal Abnormal Check the ignition coil resistance Replace the ignition coil. and high pressure cable, high pressure insulation cap. Normal Abnormal Readjust air gap. Check ignition coil air gap. Normal Inspection or replace wire harness. PH2100PRI SM 04-27-2011...

  • Page 19: Engine Oil Level Is Low, But Engine Does Not Stop

    Abnormal Readjust the coil clearance Check ignition coil Normal 1. Check the valve clearance 2. Check the carbon deposit Abnormal Measure the cylinder compression in combustion chamber 3. Check the piston, piston ring and cylinder for damage PH2100PRI SM 04-27-2011...

  • Page 20: Engine Speed Can"T Increase Or Unstable (Choke Is At The Correct Position)

    Check the throttle control motor Replace the throttle control motor Normal Abnormal Check the Economy switch Replace the Economy switch Normal Abnormal Check Economy switch connection wire Repair or replace the wire harness Normal Replace the inverter unit PH2100PRI SM 04-27-2011...

  • Page 21: Engine Speed Doesn"T Increase With Economy System "On" And A Load Connected

    1. Check and repair stator wire black terminals and white terminal. Abnormal harness or replace stator. 2. Rotor inner magnetism Black-Black-Black: ＞30V decreases, replace the rotor. White-White: ＞1V Normal Measure stator output with unit running. Abnormal Replace the stator. PH2100PRI SM 04-27-2011...

  • Page 22: Measuring Stator Output Voltage While Running

    If the wire harness is the problem, look for and repair the damage. 3. If the alternator is the problem, the stator will need to be replaced. If all three tests are OK, the problem is likely the inverter. PH2100PRI SM 04-27-2011...

  • Page 23: No Dc Output At Receptacle

    Unplug the DC charge windings from Abnormal the voltage regulator and measure Check the wire harness, or replace the resistance. the stator. Resistance: 0.3 Ω +/- 10% Normal Replace the voltage regulator. DC Battery Charge To the Windings Voltage from Stator Regulator PH2100PRI SM 04-27-2011...

  • Page 24: Voltage Regulator

    3.14 Voltage regulator Control Panel Inverter Harness Chassis Battery Ground Terminal Ignition Switch Voltage Starter Regulator Solenoid Stator Starter Solenoid Chassis Ground Terminal PH2100PRI SM 04-27-2011...

  • Page 25: Starter Motor Doesn"T Run

    Replace the starter motor Check the starter motor. Normal Check, repair or change main harness wire. Cable from Starter Starter Motor Solenoid Starter Motor Terminal Battery Terminal Voltage Regulator Start Wire Solenoid from Ignition Switch Chassis Ground PH2100PRI SM 04-27-2011...

  • Page 26: No Output When Operating In Parallel

    Note, the Economy Switch automatically turns off when running in parallel.  Two separate PH2100PRi models can run in parallel to increase the total output to a maximum load of 4200 W (Rated output, 5200 W).  You can also run a PH2700PRi and a PH2100PRi in parallel. The maximum output will be 4200 W (Rated output, 4000 W).

  • Page 27: Parallel Operating Procedure

     The required output of the electrical appliance cannot exceed the rated output of the generators. The special parallel cable for the PH2100PRI and PH2700PRi is only applicable to the parallel operation of two POWERHOUSE generators. It cannot be used for paralleling three or more generators or running two different brands of generators.
  • Page 28 1. During normal operating conditions, the output indicator lights (Green) will remain illuminated. 2. If the generators are overloaded (in excess of 4200W when using two PH2100PRi units) the overload indicator light (red) will flash slowly on only one generator. The indicator lights on the other unit and the parallel kit will all be off.

  • Page 29: Troubleshooting Parallel Operation

    The green indicator light on both generators and the parallel kit should come on within 15 seconds. Repeatedly pressing the reset button without correcting the short circuit may cause permanent damage to the generators and/or parallel kit. PH2100PRI SM 04-27-2011...
  • Page 30 Remove or reduce excessive loads. output from generators and parallel connected to either the parallel panel are on. The 30A or 20A receptacle Reset circuit breakers. panel generators are running on the parallel panel. at high idle. PH2100PRI SM 04-27-2011...

  • Page 31: Maintenance Schedule

    (1) For commercial use, operation hours are determined by proper maintenance. (2) Service more frequently when operating in dusty areas, every 10 hrs or every day. (3) Service by POWERHOUSE authorized agency, unless correct tools or professional specialist is available. Do service according to the manual.

  • Page 32: Checking The Oil Level

    5. Refill with the recommended oil, and check the oil level. 6. Reinstall the access panel and tighten the screws securely. Engine oil capacity: 15.6 oz (460 ml) Drain Pipe Upper Level Upper Level Lower Level Oil Fill Hole Dip Stick PH2100PRI SM 04-27-2011...
  • Page 33 Failure to do so can lead to permanent damage if the engine runs low on oil. Female Connector to module Oil Sensor Connector Male Connector Check Continuity between the Male connector from the Oil sensor Lead and Ground PH2100PRI SM 04-27-2011...
  • Page 34 If the engine is operated in dusty areas, clean the air cleaner more often than specified in the Maintenance Schedule.  Never run the engine without an element or the filter is damaged, as it will do great harm to the engine. PH2100PRI SM 04-27-2011...
  • Page 35 Spark plug clearance 0.6~0.7mm (0.024”~0.028”) Standard spark plug A7RTC 0. 6- 0. 7 5. Install the plug finger tight to seat the washer, and then tighten with a plug wrench. Torque valve is 9.6~11 lbs-ft (13~15 Nm) PH2100PRI SM 04-27-2011...
  • Page 36 11. Turn the rotor to set the piston at top dead center of the compression stroke. The timing mark of camshaft should be vertical to the cylinder head seal, check whether the inlet and exhaust valve are closed. Timing Mark PH2100PRI SM 04-27-2011...
  • Page 37 After tightening the lock nut, check the valve clearance again. 13. Clean the cylinder block and cylinder head cover. Adjustment Screw Lock Nut Feeler Gauge 14. Replace the rubber seal. 15. Install the removed parts in the reverse order of removal. Rubber Seal PH2100PRI SM 04-27-2011...

  • Page 38: Evaporation Control

    7. Install the removed parts in the reverse order of removal. Fill the fuel tank with gasoline and check the fuel hoses for gasoline leaks. 4.9 Evaporation Control Fuel Tank Vent To Air Filter Air Filter Assembly Fuel Tank Carbon Canister PH2100PRI SM 04-27-2011...
  • Page 39 9. Check the fuel valve and make sure there is no obstruction when open. Clean or replace as required. 10. After reassembly check all hoses and connections for fuel leaks. Fuel Primmer Bulb Valve To Intake manifold To Carburetor To Gas Tank Fuel Pump PH2100PRI SM 04-27-2011...

  • Page 40: Muffler System

    2. Remove the two M4 screws holding the spark arrester to the muffler. 3. Use a stiff wire brush to remove carbon deposits from the spark arrester screen. 4. Inspect the screen for holes, and replace it if necessary. Spark Arrestor M4 Screws Muffler Grill M6 Screws PH2100PRI SM 04-27-2011...
  • Page 41 4. Remove the left and right cover 5. Remove fuel tank. 6. Remove the carburetor assembly. 7. Remove the carbon canister. 8. Remove the starter motor. 9. Remove front and back engine covers. Exhaust Manifold Muffler gasket Muffler PH2100PRI SM 04-27-2011...
  • Page 42 5.3 Exhaust tube, secondary air valve Disassembly/Reassembly 1. Disconnect the battery. 2. Remove front and rear panel. 3. Remove right cover Secondary Air Valve PH2100PRI SM 04-27-2011...

  • Page 43: Carburetor

    4. Drain fuel from carburetor. 5. Remove two carburetor mounting bolts. 6. Remove the carburetor, choke and air filter as an assembly being very careful not to pull on the step motor wires. Choke Pot Mounting Bolts Right Canister Hose PH2100PRI SM 04-27-2011...
  • Page 44 Step motor 步进电机座 Step motor base 拔叉弹簧 Fork spring 拔叉 拆卸： Disassembly: Fork 拆卸时用手捏牢， Carefully remove 以防弹簧丢失。 the spring and fork 拔叉 油门杆 Fork from the throttle Throttle level 拔叉弹簧 lever. Fork spring 怠速调整限位帽 Idle adjusting cap PH2100PRI SM 04-27-2011...
  • Page 45 组装： 安装后应当用手指触 Float 动，对其动作确认。 Fuel cup 油杯 油杯锁紧螺丝密封圈 Seal ring Drain screw 油杯放油螺栓 油杯螺栓 Installation: check the Fuel cup bolt 组装： 组装： fuel leakage before Installation: check the 安装后确认没有燃油 安装后确认没有燃油 installation fuel leakage before 漏出。 漏出。 installation PH2100PRI SM 04-27-2011...
  • Page 46 Make sure to check the step motor connection on the inverter for any debris, damaged or bent pins Measure the resistance of the step motor lead-out wire. Replace the step motor if the resistance exceeds the ranges shown below. 1-blue ~ 2-white：50~55Ω Standard resistance 3-red ~ 4-black：50~55Ω PH2100PRI SM 04-27-2011...
  • Page 47 6.5 Automatic choke inspection/adjustment. The choke on the PH2100PRi operates automatically. When the unit is off, the choke will return to the closed position 1. The automatic choke consists of the backpressure check valve and the vacuum pot, figure 1.

  • Page 48: Control Panel

    Remove six M4 panel screws. Parallel Power Socket Parallel Signal Ignition Port Switch Indicator Module Module Cover Button Guard Stop / Reset Buttons 120V~20A Circuit Breaker DC Battery Charge DC Circuit Receptacle 120V~20A Breaker Duplex Covers Economy / Remote Switches PH2100PRI SM 04-27-2011...

  • Page 49: Outer Generator Housing

    8. Outer generator housing 8.1 Disassembly and installation of housing case Spark Plug Access Exhaust Grill Maintenance Cover Inverter Right Case Control Panel Panel Frame Left Case Fuel Pump Primmer Bulb Fuel Lever Fuel Valve Battery Access Cover PH2100PRI SM 04-27-2011...

  • Page 50: Recoil Starter / Electric Starter / Ignition Coil

    4. Drain all gasoline from the fuel tank. 5. Remove the fuel tank and the inverter. 6. Remove (3) M6 flange bolts and the recoil starter. 7. Reinstall the inverter side covers and end panels. Battery Box Inverter PH2100PRI SM 04-27-2011...
  • Page 51 1. Disconnect the battery. 2. Remove front and rear panels. 3. Remove the left and right covers 4. Using and 8mm socket remove 2-mounting bolt. 5. Remove the starter and the cable. Starter Relay Cable Screw Mounting Bolts PH2100PRI SM 04-27-2011...
  • Page 52 If there is no continuity the relay is defective. 3. Note, there must only be continuity between the battery and the starter terminals when the relay is activated. Checking Resistance Checking Continuity Connect 12volts + Connect 12volt Negative. PH2100PRI SM 04-27-2011...
  • Page 53 6. If there is no resistance remove the spark plug cap and check the lead itself. 7. Replace the spark plug cap or coil if there is no resistance or the value is outside of the values shown. 5-8 k Ω Secondary resistance PH2100PRI SM 04-27-2011...
  • Page 54 (Both sides need to be adjusted equally) and retighten the bolts. 3. Rotate the rotor to make sure there is interference with the flyweights. Ignition coil gap 0.5~0.75mm Ignition Coil Permanent magnet Rotor PH2100PRI SM 04-27-2011...

  • Page 55: Rotor/Stator Disassembly / Reassembly

     Inverter.  Fan cover  Starter cup and fan  M12 flange nut  Ignition coil  Rotor  M5 Stator bolts  Stator Ignition Coil Stator Assembly Rotor Assembly Flange Bolts Flange Nut Starter cup PH2100PRI SM 04-27-2011...
  • Page 56 Measure the resistance between the two sub winding terminals. White-White Resistance Ω 0.100~0.160 (4) Main winding Measure the resistance between each of the main winding terminals. Black-Black-Black Resistance Ω 0.250~0.350 Main Windings, (Black) Windings, (White) DC Battery Charge Windings, (Blue) PH2100PRI SM 04-27-2011...
  • Page 57 11. Exploded engine view PH2100PRI SM 04-27-2011...
  • Page 58 "O" style sealing ring 09070129-31 69706 Tie bar bolt 03050313 69715 Rear oil seal 040906-07 Timing chain guide, tensioner 09070111 69701 Timing chain 09070112 69701 Timing chain guide 09070109 69705 Retainer ring 09070139 69708 Locating pin for piston 09070102 PH2100PRI SM 04-27-2011...
  • Page 59 M6 x 100 bolt 03050226 Camshaft 09070128 69669 Rocker subassembly 09070133 69644 M8 nut 03060115 69709 Valve cover gasket 09070110 69667 53, 54, Valve cover/PCV Assy. 77050 Need 58 & 59 M6 x 25 bolt 03050241 69349 PH2100PRI SM 04-27-2011...
  • Page 60 2. The timing mark of camshaft should be vertical to the cylinder head seal, check whether the inlet and exhaust valve are closed. 3. Remove 4- rocker arm nuts and washers and carefully remove the rocker arm assembly Timing Mark Alignment Sleeves PH2100PRI SM 04-27-2011...
  • Page 61 12.2 Rocker Arm Inspection ● Rocker arm outer diameter Standard Service limit 9.96—9.97mm 9.953mm (0.392-0.393”) (0.391”) ● Rocker arm inner diameter of inlet/exhaust valve Standard Service limit 10.000-10.015mm 10.040mm (0.3936-0.3942”) (0.3952”) PH2100PRI SM 04-27-2011...
  • Page 62 5. Lift and remove the cam assembly from the head. 6. Carefully inspect the cam lobes, bearings and decompression operation. ● Cam height Standard Service limit 29.026-29.086 mm (1.143-1.145”) 29.15 mm (1.104”) Timing Chain Tensioner Cam Bearings Decompression Intake Exhaust Fly Weight Decompression Decompression “ON” “OFF” PH2100PRI SM 04-27-2011...
  • Page 63 (Upright) position.  Install the chain onto the cam gear making sure that the timing mark is straight up before installing the rocker arm assembly. Timing Timing Mark Mark Crankshaft Keyway PH2100PRI SM 04-27-2011...
  • Page 64 13. Constant clockwise tension must be applied to the center screw until the tensioner is flush with the gasket before it is released. Rotate tension Screw Clockwise to Retract plunger Adjustment Screw Cover and ‘O’-Ring Normal Position The Plunger must be kept in the retracted position while reinstalling. PH2100PRI SM 04-27-2011...
  • Page 65 ● Valve stem outer diameter Standard Service limit 4.92mm (0.1937”) 4.975 - 4.99mm (0.1958-0.1964”) Intake valve 4.90mm (0.193”) 4.955 - 4.970mm (0.1950-0.1951”) Exhaust valve ● Valve guide inner diameter Standard Service limit 5.000-5.030mm (0.197-0.198”) 5.060mm (0.199”) Inlet/Exhaust valve PH2100PRI SM 04-27-2011...
  • Page 66 连杆 组装： Connection rod Installation: 将大端部较长的一侧朝向活塞的 The larger side of the “ ” 指向的右侧装入活塞 。 卡环 connection rod must be Clip ring aligned with the △ label on the piston. PH2100PRI SM 04-27-2011...
  • Page 67 ● Piston skirt outer diameter Standard Service limit 52.360-52.380mm (2.061-2.062”) 52.25mm (2.057”) Piston pin clip 10m m ● Side clearance of piston ring Standard Service limit 0.15mm (0.0059”) 0.02-0.06mm (0.0008-0.0024”) and 2 Ring 0.24mm (0.009”) 0.03-0.18mm (0.001-0.007”) Oil Ring PH2100PRI SM 04-27-2011...
  • Page 68 Locate the piston ring into cylinder with piston top, and measure the piston end clearance. Standard Service limit 1.0mm (0.039”) 0.15-0.25mm (0.0059-0.0098”) and 2 Ring 1.0mm (0.039”) 0.20-0.50mm (0.0078-0.0196”) Oil Rings ● Piston ring height Standard Service limit 0.87mm (0.0342”) 0.97-0.99mm (0.0381-0.0389”) and 2 Ring 1.75mm (0.0688”) 1.85-1.96mm (0.0728-0.0771”) Oil Rings PH2100PRI SM 04-27-2011...
  • Page 69 ● Piston pin outer diameter Standard Service limit 14.95mm (0.5925”) 14.994-15.008mm (0.5903-0.5905”) ● Piston pin hole inner diameter Standard Service limit 15.05mm (0.5925”) 15.002-15.008mm (0.5907-0.5908”) ● Connection rod small end inner diameter Standard Service limit 15.08mm (0.594”) 15.006-15.017mm (0.590-0.5991”) PH2100PRI SM 04-27-2011...

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