Powerhouse PH2700PRi Shop Manual
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Powerhouse PH2700PRi Shop Manual

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POWERHOUSE
®
POWERHOUSE POWER PRODUCTS
PH2700PRi SHOP MANUAL
Coast Distribution
November, 2010
1
PH2700PRI SM 11-09-2010

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  • Page 1 POWERHOUSE ® POWERHOUSE POWER PRODUCTS PH2700PRi SHOP MANUAL Coast Distribution November, 2010 PH2700PRI SM 11-09-2010...

  • Page 2: Preface

    Preface This manual covers the construction, function and servicing procedure of the POWERHOUSE® certificated by CARB. PH2700PRi generator, 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

    3.22 Troubleshooting Parallel Operation ......................31 3.23 Troubleshooting Parallel Operation (Cont.) ....................32 4.Maintenance ............................33 4.1 Maintenance schedule ..........................33 4.2 Checking the oil level ..........................34 4.3 Changing oil ..............................34 4.4 Checking for the low oil sensor ........................35 PH2700PRI SM 11-09-2010...
  • Page 4 12. Valve cover/ Rocker arm ........................62 12.1 Disassembly/ Reassembly.......................... 62 12.2 Rocker Arm Inspection ..........................63 12.3 Cam and cylinder head removal / Reassembly ..................64 12.4 Inspection, valves and valve springs ......................67 12.5 Piston/Connection rod ..........................68 PH2700PRI SM 11-09-2010...

  • Page 5: Specifications

    Semi-dry type Governor Electronic control Lubrication system Pump Lube oil SAE 15W-40 (SF/SG grade or greater) Oil capacity 16 oz (0.5 L) Starting system Remote, Electric, & Recoil Stopping system Primary circuit ground Fuel used Automotive unleaded gasoline PH2700PRI SM 11-09-2010...

  • Page 6: Characteristics

    2 x 20A DC circuit protector Fuel tank capacity 1.4 gal (5.2L) Continuous running time 2.9 / 7.2 hours (at Rated load / at ¼ load) 58-67 dB @ 23‟ (7m) Noise level (Zero load to full load) PH2700PRI SM 11-09-2010...

  • Page 7: Wiring Diagram

    1.3 WIRING DIAGRAM PH2700PRI SM 11-09-2010...

  • Page 8: Service Information

    To reduce the possibility of a fire or explosion, be careful when working around gasoline. Use only a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away from fuel and all fuel-related parts. PH2700PRI SM 11-09-2010...

  • 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”) PH2700PRI SM 11-09-2010...

  • Page 11: Motor

    Primary side 0.045-0.070Ω Ignition coil Resistance 5-8k Ω — Second side 2.6 Motor Standard(Ω) Part Item Wire color 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 PH2700PRI SM 11-09-2010...

  • Page 12: Torque Values

    Crankcase cover 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. PH2700PRI SM 11-09-2010...

  • Page 13: Trouble Shooting

    Inspect / disassemble and clean Economy switch Inspect Engine speed does not Throttle control motor (step motor) Inspect wiring / inspect motor stabilize, too faulty high or too low Inverter unit faulty Inspect / replace Valve clearance misadjusted Readjust PH2700PRI SM 11-09-2010...

  • Page 14: Difficult Cold Starting

    The choke on the PH2700PRi operates automatically. When the unit is off, the choke will return to the closed position. In some cases, the choke on the PH2700PRi may close too slowly or open too fast. Both conditions can cause difficulty starting the unit. Read below to see if one or both conditions are present.

  • Page 15: Hard Starting

    3. Check the valve cone and seat several times 4. Check for worn piston, piston ring or cylinder. Normal compression Install the spark plug securely. Restart the engine according to the starting procedure. PH2700PRI SM 11-09-2010...

  • Page 16: Cylinder Compression Check

    2. Install a compression gauge in the spark plug hole. 3. Push the remote switch to the OFF position. 4. Turn the ignition switch to the start position and measure the cylinder compression. Cylinder compression 0.45Mpa (65 psi) /800rpm Pressure Gauge Remote Switch PH2700PRI SM 11-09-2010...

  • Page 17: Ignition System

    Turn the ignition switch to the “ON” position. Attach the negative (—) electrode (i.e. threaded part) of the spark plug to your ground wire and pull the recoil starter rope to check the spark plug. Ground Wire Spark Plug Spark Plug Wire PH2700PRI SM 11-09-2010...
  • Page 18 Normal Check the ignition coil resistance Abnormal Replace the ignition coil and high pressure cable, high pressure insulation cap. Normal Abnormal Check ignition coil air gap Readjust air gap Normal Inspect or replace wire harness. PH2700PRI SM 11-09-2010...

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

    Abnormal Readjust the coil clearance Check ignition coil 1. Check the valve clearance Normal 2. Check the carbon deposit Abnormal in combustion chamber Measure the cylinder compression 3. Check the piston, piston ring and cylinder for damage PH2700PRI SM 11-09-2010...

  • Page 20: Engine Speed Can't Increase Or Is Unstable (Choke Is In 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 PH2700PRI SM 11-09-2010...

  • 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 stator PH2700PRI SM 11-09-2010...

  • 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 probably the inverter. PH2700PRI SM 11-09-2010...

  • Page 23: No Dc Output At Battery Charge Receptacle

    Unplug the DC charge windings from Abnormal the voltage regulator and measure Check the wire harness, the resistance. Resistance: 0.3 Ω +/- 10% or replace the stator Normal Replace the voltage regulator DC Battery Charge To the Windings Voltage from Stator Regulator PH2700PRI SM 11-09-2010...

  • Page 24: Voltage Regulator

    3.15 Voltage regulator Control panel Inverter harness Chassis Ground Battery Terminal Ignition Switch Voltage Starter Regulator Solenoid Stator Starter solenoid Chassis Ground Terminal PH2700PRI SM 11-09-2010...

  • Page 25: Engine Will Not Start Or Stop With Remote

    4. If the unit will now start and continue to run replace the receiver and transmitters. Note, with the receiver unplugged, the generator will not shut off using the ignition switch. To shut down the unit, reconnect the receiver or turn off the fuel lever. PH2700PRI SM 11-09-2010...

  • Page 26: Engine Will Not Shut Off With Ignition Key, Remote Or Stop Button

    6. Check the 6-pin connection between the remote receiver and control panel looking for any loose or broken wires. If no problems are found replace the remote receiver. Control panel Inverter harness Chassis Ground Battery Terminal Ignition Switch Voltage Starter Regulator Solenoid Stator Starter solenoid Chassis Ground Terminal PH2700PRI SM 11-09-2010...

  • Page 27: No Electric Start

    Replace the starter motor Check the starter motor Normal Check, repair or change main harness wires Cable from Starter Starter Motor Solenoid Starter Motor Terminal Battery Terminal Voltage Regulator Start Wire Solenoid from Ignition Switch Chassis PH2700PRI SM 11-09-2010 Ground...

  • Page 28: Parallel No Output

    Note, The Economy Switch automatically turns off when running in parallel.  Two separate PH2700PRi models can run in parallel to increase the total output to a maximum load of 5400 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 29: Parallel Operation Procedure

     The required output of the electrical appliance cannot exceed the rated output of the generators. The special parallel cable for the PH2700PRI and PH2100PRi 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 30 1. During normal operating conditions, the output indicator lights (Green) will remain illuminated. 2. If the generators are overloaded (in excess of 5200W when using two PH2700PRi 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 31: 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. PH2700PRI SM 11-09-2010...

  • Page 32: Troubleshooting Parallel Operation (Cont.)

    Remove or reduce excessive loads. No AC output from generators and parallel connected to either the Reset circuit breakers. parallel panel are on. The 30A or 20A receptacle generators are running on the parallel panel. panel at high idle. PH2700PRI SM 11-09-2010...

  • Page 33: Maintenance

    (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 34: Checking The Oil Level

    4. Drain dirty oil into a container. Allow enough time for the oil to drain completely. 5. Refill with the recommended oil, and check the oil level. 6. Reinstall the access panel and tighten the screws securely. Engine oil capacity: 16oz. (0.50L) Drain Pipe Upper Level Upper Level Lower Level Dipstick PH2700PRI SM 11-09-2010...

  • Page 35: Checking For The Low Oil Sensor

    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 PH2700PRI SM 11-09-2010...

  • Page 36: Air Cleaner

    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. PH2700PRI SM 11-09-2010...

  • Page 37: Spark Plug

    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) PH2700PRI SM 11-09-2010...

  • Page 38: Valve Clearance

    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 PH2700PRI SM 11-09-2010...
  • Page 39 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 PH2700PRI SM 11-09-2010...

  • Page 40: Fuel Tank

    7. Install the removed parts in the reverse order of removal. 8. Fill the fuel tank with gasoline and check the fuel hoses for gasoline leaks. 4.9 Evaporation Control Fuel Tank Vent Air Filter To Air Filter Fuel Tank Carbon Canister PH2700PRI SM 11-09-2010...

  • Page 41: Fuel Pump, Primer Bulb

    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 PH2700PRI SM 11-09-2010...

  • Page 42: 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 PH2700PRI SM 11-09-2010...

  • Page 43: Muffler

    6. Remove the carburetor assembly. 7. Remove the carbon canister. 8. Remove the starter motor. 9. Remove front and back engine covers. Muffler Gasket Muffler Spark Arrestor Muffler Bolts Manifold Bolts “DO NOT” Remove the Bolts Chain Tension PH2700PRI SM 11-09-2010...

  • Page 44: Exhaust Tube, Secondary Air Valve

    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 PH2700PRI SM 11-09-2010...

  • Page 45: Carburetor

    6. Remove the carburetor and choke as an assembly being very careful not to pull on the step motor wires. Fig. 1 Fig. 2 Mounting Cover Screw Bolts Right Vent Hose Choke Pot Carbon Canister Air Cleaner assembly PH2700PRI SM 11-09-2010...

  • Page 46: Disassembly/Installation Of Step Motor

    Step motor 步进电机座 Step motor base 拔叉弹簧 Fork spring 拔叉 Disassembly: 拆卸： Fork 拆卸时用手捏牢， Carefully remove 以防弹簧丢失。 拔叉 the spring and fork Fork 油门杆 Throttle level from the throttle Fork spring 拔叉弹簧 lever. Idle adjusting cap 怠速调整限位帽 PH2700PRI SM 11-09-2010...

  • Page 47: Disassembly/Reassembly Of Carburetor

    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 Fuel cup bolt Installation: check the 组装： 组装： Installation: check the fuel leakage before 安装后确认没有燃油 安装后确认没有燃油 fuel leakage before installation 漏出。 漏出。 installation PH2700PRI SM 11-09-2010...

  • Page 48: Step Motor Inspection

    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 PH2700PRI SM 11-09-2010...

  • Page 49: Automatic Choke Inspection/Adjustment

    6.5 Automatic choke inspection/adjustment. The choke on the PH2700PRi 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 50: Control Panel

    Panel Screws Indicator Module Parallel Power Socket Ignition Parallel Signal Switch Port Module Cover Button Guard Stop / Reset Buttons DC Battery 120V~20A Charge Circuit Receptacle Breakers 120V~20A DC Circuit Economy / Remote Breaker Duplex, Switches Split PH2700PRI SM 11-09-2010...

  • Page 51: Outer Generator Housing

    8.1 Disassembly and installation of housing case Exhaust Grill Maintenance Cover Inverter Pull Cord Handle Battery Spark Plug Access Primmer Bulb Right Side Case Control Panel Fuel Pump Panel Frame Fuel Valve Battery Access Handle / Axle Assembly Cover Fuel Lever Rubber Feet PH2700PRI SM 11-09-2010...

  • Page 52: 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 PH2700PRI SM 11-09-2010...

  • Page 53: Starter Motor

    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 PH2700PRI SM 11-09-2010...

  • Page 54: Starter Relay

    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. PH2700PRI SM 11-09-2010...

  • Page 55: Ignition Coil

    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. 12.7 k Ω +/- 10% Secondary resistance PH2700PRI SM 11-09-2010...

  • Page 56: Ignition Coil/Disassembly

    (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 clearance 0.5-0.75mm Ignition Coil Permanent magnet Rotor PH2700PRI SM 11-09-2010...

  • Page 57: 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 PH2700PRI SM 11-09-2010...

  • Page 58: Stator Inspection

    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) PH2700PRI SM 11-09-2010...

  • Page 59: Exploded Engine View

    11. Exploded engine view PH2700PRI SM 11-09-2010...
  • Page 60 "O" style sealing ring 09070129-31 69706 Tie bar bolt 03050313 69715 Rear oil seal 040907 Timing chain guide 09070111 69701 Timing chain 09070112 69702 Timing chain guide 09070109 69705 Retainer ring 09070139 69708 Located pin for piston 09070102 PH2700PRI SM 11-09-2010...
  • Page 61 09070125 69682 M6 x 100 bolt 03050226 Camshaft 09070128 69669 Rocker assy. (includes 53 & 54) 09070133 69644 M8 nut 03060115 69709 Valve cover gasket 09070110 69667 Valve cover/PCV Assy. 77050 M6 x 25 bolt 03050241 69349 PH2700PRI SM 11-09-2010...

  • Page 62: Valve Cover/ Rocker Arm

    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 bolts and carefully remove the rocker arm assembly Timing Mark Alignment Sleeves PH2700PRI SM 11-09-2010...

  • Page 63: Rocker Arm Inspection

    12.2 Rocker Arm Inspection ● Rocker arm outer diameter Standard Service limit 9.96-9.975mm ( ) 9.953mm ( ) ● Rocker arm inner diameter of inlet/exhaust valve Standard(mm) Service limit(mm) 10.000-10.015 ( ) 10.040 ( ) PH2700PRI SM 11-09-2010...

  • Page 64: Cam And Cylinder Head Removal / Reassembly

    5. Lift and remove the cam assembly from the head. 6. Carefully inspect the cam lobes, bearings and decompression operation. ● Cam height Standard(mm) Service limit(mm) 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” PH2700PRI SM 11-09-2010...
  • Page 65 Make sure that the piston is at top dead center which can also be confirmed by locating the crank shaft keyway in the vertical (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 PH2700PRI SM 11-09-2010...
  • Page 66 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. PH2700PRI SM 11-09-2010...

  • Page 67: Inspection, Valves And Valve Springs

    Small 32.8mm (1.291”) 33.8mm (1.330”) Large ● Valve seat width Standard Service limit 1.0mm (0.039”) 2.0mm (0.079”) ● Valve stem outer diameter Standard Service limit 4.975-4.99mm (0.1958”-0.1964”) 4.92mm (0.1937”) Intake valve 4.955-4.970mm (0.1950”-0.1951”) 4.90mm (0.193”) Exhaust valve PH2700PRI SM 11-09-2010...

  • Page 68: Piston/Connection Rod

    连杆 Connection rod Installation: 组装： 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 。 connection rod must be 卡环 Clip ring aligned with the △ label on the piston. PH2700PRI SM 11-09-2010...
  • Page 69 ● Piston skirt outer diameter Standard Service limit 57.960-57.980mm (2.281”-2.282”) 57.85mm (2.277”) Piston pin clip 10m m ● Side clearance of piston ring Standard Service limit 0.02-0.06mm (0.0008”-0.0024”) 0.15mm (0.0059”) and 2 Ring 0.03-0.18mm (0.001”-0.007”) 0.24mm (0.009”) Oil Ring PH2700PRI SM 11-09-2010...
  • Page 70 Locate the piston ring into cylinder with piston top, and measure the piston end clearance. Standard Service limit 0.15-0.25mm (0.0059”-0.0098”) 1.0mm (0.039”) and 2 Ring 0.20-0.50mm (0.0078”-0.0196”) 1.0mm (0.039”) Oil Rings ● Piston ring height Standard Service limit 0.97-0.99mm (0.0381”-0.0389”) 0.87mm (0.0342”) and 2 Ring 1.85-1.96mm (0.0728”-0.0771”) 1.75mm (0.0688”) Oil Rings PH2700PRI SM 11-09-2010...
  • Page 71 ● Piston pin outer diameter Standard Service limit(mm) 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”) PH2700PRI SM 11-09-2010...

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