Powerhouse PH3100RI Shop Manual
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Powerhouse PH3100RI Shop Manual

Digital inverter generator
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POWERHOUSE
®
PH3100RI Digital Inverter Generator
SHOP MANUAL
Coast Distribution System
March 2014

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Summary of Contents for Powerhouse PH3100RI

  • Page 1 POWERHOUSE ® PH3100RI Digital Inverter Generator SHOP MANUAL Coast Distribution System March 2014...

  • Page 2: Preface

    PREFACE This manual covers the construction, function and servicing procedure of the POWERHOUSE® PH3100Ri certificated by CARB. generator, Careful observance of these instructions will result in better, safer 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

    3.18 Engine will start and then shut down........................30 4. Maintenance ................................. 31 4.1 Maintenance schedule ............................31 4.2 Checking the oil level ............................32 4.3 Changing oil ................................33 4.4 Checking the low oil sensor ........................... 34 4.5 Air Cleaner ................................35 PH3100Ri SM Revision 03-03-2014r1...
  • Page 4 12.2 Cylinder Head Disassembly and Reassembly...................... 60 12.3 Inspection................................61 13. Crankshaft / Piston ..............................62 13.1 Crankshaft, camshaft and piston .......................... 62 13.2 Alignment of timing marks ..........................63 13.3 Camshaft Inspection ............................64 13.4 Piston / Connection rod ............................65 PH3100Ri SM Revision 03-03-2014r1...
  • Page 5 PH3100Ri SM Revision 03-03-2014r1...

  • Page 6: Specifications

    270cc Bore x stroke 77 × 58 Maximum horsepower Compression ratio 9.2:1 Cooling system Forced air-cooled Ignition system Electronic Spark plug F7RTC Carburetor Horizontal, Float type Air cleaner Semi-dry type Governor Electronic control Lubrication system Splash PH3100Ri SM Revision 03-03-2014r1...

  • Page 7: Characteristics

    10%max. Average 1.5%max. Average time 3 sec. max. Voltage stability ±1% Frequency variation rate Momentary 1%max. Average 1%max. Average time 1 sec. max. Frequency stability ±0.1% 10MΩmin. Insulation resistance AC circuit protector 20A and 30A (120V) PH3100Ri SM Revision 03-03-2014r1...
  • Page 8 DC circuit protector Fuel tank capacity 4.4 gal (16.6L) Continuous running time 7.6 hours / 17.8 hours (at rated load / at ¼ load) 56-65 dB @ 23’ (7m) Noise level (Zero load to full load) PH3100Ri SM Revision 03-03-2014r1...

  • Page 9: Wiring Diagram W/O Electric Choke Solenoid

    1.3 Wiring Diagram w/o electric choke solenoid PH3100Ri SM Revision 03-03-2014r1...

  • Page 10: Wiring Diagram With Electric Choke Solenoid, Beginning With S/N 100602380706001

    1.4 Wiring Diagram with electric choke solenoid, beginning with S/N 100602380706001 CHOKE PH3100Ri SM Revision 03-03-2014r1...

  • Page 11: 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. PH3100Ri SM Revision 03-03-2014r1...

  • Page 12: 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 13: Serial Number Location

    17.994-17.000mm 17.95mm Piston pin (0.7084”-0.7087”) (0.7067”) 1.97-1.99mm 1.87mm Height h (0.0776”-0.0783”) (0.0736”) 0.02-0.06mm 0.15mm Ring side clearance (0.006”) (0.001”-0.002”) Piston ring 1st ring 0.15-0.25mm 1.0mm Ring end clearance (0.006”-0.010”) (0.04”) 3.40-3.60mm 3.20mm Width t (0.134”-0.142”) (0.126”) PH3100Ri SM Revision 03-03-2014r1...
  • Page 14 Cam wheel Cam height (1.2480”-1.2512”) (1.2205”) 0.8mm (.032”) — Main jet — Carburetor Float height — Pilot screw opening (Fixed) 0.6-0.7mm — Spark plug (0.024”-0.028”) 1.4-2.0 Ω — Primary side Ignition coil Resistance — Second side 11.0-15.0kΩ PH3100Ri SM Revision 03-03-2014r1...

  • Page 15: Motor

    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 PH3100Ri SM Revision 03-03-2014r1...

  • Page 16: 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. PH3100Ri SM Revision 03-03-2014r1...

  • Page 17: 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 PH3100Ri SM Revision 03-03-2014r1...

  • Page 18: 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 Spark Plug Boot Wire PH3100Ri SM Revision 03-03-2014r1...
  • Page 19 Replace the ignition coil insulation cap. Normal Abnormal Check the BFP controller Replace the BFP controller Normal Abnormal Readjust air gap Check ignition coil air gap Normal Inspect or replace wire harness. PH3100Ri SM Revision 03-03-2014r1...

  • Page 20: Engine Oil Level Is Low, But Engine Does Not Stop

    Check ignition coil Readjust the coil clearance Normal 1. Check the valve clearance. Abnormal 2. Check the carbon deposit in Measure the cylinder compression combustion chamber. 3. Check the piston, piston ring and cylinder for damage. PH3100Ri SM Revision 03-03-2014r1...

  • Page 21: 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 PH3100Ri SM Revision 03-03-2014r1...

  • Page 22: 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 decreased, replace the rotor White-White: ＞1V Normal Abnormal Measure stator output with unit running Replace stator PH3100Ri SM Revision 03-03-2014r1...

  • Page 23: 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. PH3100Ri SM Revision 03-03-2014r1...

  • Page 24: No Dc Output At Battery Charge Receptacle

    Unplug the DC charge windings from Abnormal the voltage regulator and measure Check the wiring harness or the resistance. replace the stator Resistance: 0.045 - 0.070Ω Normal Replace the voltage regulator DC Battery Charge To the Windings Voltage from Stator Regulator PH3100Ri SM Revision 03-03-2014r1...
  • Page 25 2. The voltage to the control panel should measure 13 to 15 volts DC. Voltage Regulator Battery charge Wire to Starter Solenoid Harness Plug to Circuit Breaker and DC Receptacle To Ignition Switch Chassis Starter Ground Solenoid Spade Terminal Terminal Harness Plug to DC Stator Charge Windings PH3100Ri SM Revision 03-03-2014r1...

  • Page 26: No Electric Start

    Replace the starter motor Check the starter motor Normal Check, repair or change main harness wires Starter Motor Cable from Starter Solenoid Battery Starter Terminal motor Terminal Start Wire from Ignition Switch Starter Solenoid Chassis Ground PH3100Ri SM Revision 03-03-2014r1...

  • Page 27: Engine Will Not Shut Off With Ignition Key, Remote Or Stop Button

    If no problems are found replace the remote receiver. Voltage Regulator Battery charge Wire to Starter Solenoid Harness Plug to Circuit Breaker and DC Receptacle To Ignition Switch Chassis Starter Solenoid Ground Spade Terminal Terminal Harness Plug to DC Stator Charge Windings PH3100Ri SM Revision 03-03-2014r1...

  • Page 28: Engine Will Not Start Or Stop With Remote

    There should be 12-15 and red battery cable VDC coming from the regulator No voltage Replace Voltage regulator Abnormal Check 6-pin connection at the remote Repair or replace faulty connections receiver Replace the remote transmitters and receiver PH3100Ri SM Revision 03-03-2014r1...

  • Page 29: Engine Will Struggle When Shut Off With Key Or Remote, But Keeps Running Rough

    If there is no 12 VDC, replace the BFP controller. (BFP) (Green/Black) Connects to Fuel Shutoff Solenoid (Red/Black) Connects to DC Power Supply from Voltage Regulator Connects to Connects to the Ignition the Ignition Switch Coil PH3100Ri SM Revision 03-03-2014r1...

  • Page 30: Engine Will Start And Then Shut Down

    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. Remote Receiver Air Filter Cover Inverter PH3100Ri SM Revision 03-03-2014r1...

  • Page 31: Maintenance

    (2) Service more frequently when operating in dusty areas, every 10 hrs or every day. (3) Service should be performed by a POWERHOUSE® authorized agency, unless correct tools and a professional specialist are available. Service should always be performed according to the service manual.

  • Page 32: Checking The Oil Level

    2. Remove the oil filler cap and check for the oil level. 3. If the oil level is low, add oil until it reaches the edge of the oil filler port. Upper Limit Upper level Lower level Lower Limit PH3100Ri SM Revision 03-03-2014r1...

  • Page 33: Changing Oil

    Lower level Lower Limit ■ Please dispose of used motor oil in a manner that is compatible with the environment and local disposal regulations. Do not throw it in the trash or pour it on the ground. PH3100Ri SM Revision 03-03-2014r1...

  • Page 34: Checking The Low Oil Sensor

    Failure to do so can lead to permanent damage if the engine runs low on oil. White Lead to the Indicator Module Black Lead to the Low Oil Sensor Check Continuity between the Black Oil sensor Lead and Ground PH3100Ri SM Revision 03-03-2014r1...

  • Page 35: Air Cleaner

    Maintenance Schedule. ■ Never run the engine if there is no element or if the filter is damaged, as it will cause serious damage to the engine. PH3100Ri SM Revision 03-03-2014r1...

  • Page 36: Spark Plug

    0.6-0.7mm (0.024”-0.028”) Spark plug clearance Standard spark plug F7RTC 0.6-0.7 5. Install the plug finger tight to seat the washer, and then tighten with a plug wrench. Torque valve is 8.9-11 lbf-ft (12-15 Nm) PH3100Ri SM Revision 03-03-2014r1...

  • Page 37: Valve Clearance

    1. Remove spark plug, valve cover bolt, valve cover and valve cover gasket. Spark Plug Valve Cover Gasket Valve Cover Valve Cover Bolt 4.8 Evaporation Control System Vent Hose from Air Fuel Tank Vent Hose from Tank Air Cleaner case 380cc Carbon Canister PH3100Ri SM Revision 03-03-2014r1...
  • Page 38 Adjust the screw until the desired valve clearance is attained. c. Tighten the locknut and recheck the clearance. 4. Clean the cylinder block and valve cover. 5. Replace the rubber valve cover seal. 6. Install the removed parts in the reverse order of removal. PH3100Ri SM Revision 03-03-2014r1...

  • Page 39: Muffler System

    3. Clean the spark arrestor with a stiff wire brush. 4. Replace the spark arrestor if the wire mesh is perforated or torn. 5. Reinstall the spark arrester. 6. Reinstall the exhaust grill. Spark Arrestor Clamp Exhaust Grill PH3100Ri SM Revision 03-03-2014r1...

  • Page 40: Muffler

    5. Remove the muffler. Carefully note the various length bolts and spacers during removal and reassembly. Upper Frame and Fuel Tank Muffler Cover Bolts M8x85 Gasket M8x90 Long Spacer Exhaust Fan M8x170 Short M8x150 Spacer Secondary Air valve PH3100Ri SM Revision 03-03-2014r1...

  • Page 41: Carburetor

    6. Remove flange nuts, retainer plate and air box. 7. Remove the carburetor and choke as an assembly, being careful not to pull on the step motor wires. Remote Receiver Air Filter Cover Inverter Backpressure Automatic Choke Check Valve Assembly Carburetor PH3100Ri SM Revision 03-03-2014r1...

  • Page 42: Disassembly / Installation Of Step Motor

    1. Measure the resistance of the outlet terminals of the step motor Pin 1-blue - Pin 2-white：50-55Ω Resistance value Pin 3-red - Pin 4-black：50-55Ω 2. Replace the step motor if the resistance exceeds the standard value. PH3100Ri SM Revision 03-03-2014r1...

  • Page 43: Fuel Shutoff Solenoid

    Measure resistance between these Leads 6.5 Backfire controller (BFP) (BFP) (Green/Black) Connects to the Fuel Shutoff Solenoid (Red/Black) Connects to the DC Power Supply from Voltage Regulator Connects to Connects to the Ignition the Ignition Switch Coil PH3100Ri SM Revision 03-03-2014r1...

  • Page 44: Automatic Choke Assembly

    The plunger should stay in the retracted position as long as the hose is pinched or closed off. Hose to Intake Hose to Manifold Vacuum Pot Backpressure Check Valve Choke Return Spring Choke Lever Vacuum Pot Choke linkage Hose to Backpressure Valve PH3100Ri SM Revision 03-03-2014r1...

  • Page 45: High Altitude Jet Installation

    6. Replace the main jet with a high altitude jet and reassemble carburetor. 7. Reinstall and check for fuel leaks. Rubber bowl Seal Emulsifier Tube Main Jet Fuel Bowl ‘O’-ring Fuel Cut-Off Solenoid Fuel Bowl Retainer PH3100Ri SM Revision 03-03-2014r1...

  • Page 46: Control Panel

    120V-20 & 30 12V DC Circuit amp Circuit Breaker Breakers Ignition Switch Indicator Module Module Cover Hour Meter Receptacle 120V 30amp (L5-30) Remote and Economy Ignition Key 120V 20amp Switches Duplex Overload and (5-20) Stop Buttons PH3100Ri SM Revision 03-03-2014r1...

  • Page 47: Outer Generator Housing

    Handle Sponge Oil Access Cover Fold Over Handle Rear Cover Inverter DC Voltage Regulator Battery Short Sponge Fuel Knob Fixed Control Panel Wheel Left Swivel Cove New handle, Beginning with Serial Wheel Number 100317377059001 Maintenance Cover PH3100Ri SM Revision 03-03-2014r1...

  • Page 48: Recoil Starter / Disassembly / Reassembly

    1. Disconnect the battery. 2. Remove front panel. 3. Drain all gasoline from the fuel tank. 4. Remove the inverter. 5. Remove (3) M6 flange bolts and the recoil starter. 6. Reinstall the inverter and end panel. Inverter PH3100Ri SM Revision 03-03-2014r1...

  • Page 49: Inlet Fan Cover

    6. Disconnect the starter motor wire and all ground wires. Remove (4) nuts from the engine mounting bolts (2 on each side) and lift the engine assembly off of the base pan. Upper Frame and Gas Tank Mounting Bolts PH3100Ri SM Revision 03-03-2014r1...

  • Page 50: Starter Motor

    Starter Motor Ignition Coil Rotor and Stator Assembly Starter Cup Inlet Fan 9.2 Starter motor 1. Follow steps 1 through 8 as outlined in section 8.1. 2. Remove (2) M8 flange bolts M8 Starter Motor Bolts PH3100Ri SM Revision 03-03-2014r1...

  • Page 51: Start Relay

    If there is no continuity the relay is defective. 3. Note, there must only be continuity between the battery and starter terminals when the relay is activated. Checking Resistance Checking Continuity Connect 12volts + Connect 12volt Negative. PH3100Ri SM Revision 03-03-2014r1...

  • Page 52: Ignition Coil Inspection

    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. Secondary resistance 11.0-15.0kΩ PH3100Ri SM Revision 03-03-2014r1...

  • Page 53: Ignition Coil Adjustment / Replacement

    (Both sides need to be adjusted equally) and retighten the bolts. 4. Rotate the rotor to make sure there is no interference with the flyweights. 0.6-0.8mm (0.024”-0.032”) Ignition coil clearance Feeler Gauge Ignition Coil Permanent Magnet Rotor PH3100Ri SM Revision 03-03-2014r1...

  • Page 54: Stator And Rotor Disassembly / Reassembly

    Resistance 0.10-0.16 Ω Main windings Measure the resistance between each of the main winding terminals at the 6-pin connector. Black-Black-Black Resistance 0.25-0.35 Ω 2-Pin Connector from Stator to Voltage Regulator 6-Pin Connector from Stator to Inverter PH3100Ri SM Revision 03-03-2014r1...

  • Page 55: Stator Removal/Reassembly

    12. Remove the cable retainer clip and (4) stator mounting bolts using a M5 Allen wrench. 13. Reverse the procedure to reassemble Stator Rotor Stator Rotor Nut Bolts Intake fan Starter Cup Ignition Coil M6 Bolts Cable Retainer Clip and Bolt PH3100Ri SM Revision 03-03-2014r1...

  • Page 56: Exploded Engine View

    11. Exploded engine view PH3100Ri SM Revision 03-03-2014r1...
  • Page 57 PH3100Ri SM Revision 03-03-2014r1...
  • Page 58 PH3100Ri SM Revision 03-03-2014r1...

  • Page 59: Valve Cover / Rocker Arm

    5. Remove the muffler cover, muffler, exhaust fan, exhaust manifold and muffler housing. 6. Remove the upper and lower engine covers. 7. Remove the valve cover and (4) - M10 head bolts. Muffler Muffler Cover Muffler Case Upper Engine Exhaust cover Manifold Exhaust Fan Lower Engine cover PH3100Ri SM Revision 03-03-2014r1...

  • Page 60: Cylinder Head Disassembly And Reassembly

    Breather Tube Head Gasket and Rubber Seal 12.2 Cylinder Head Disassembly and Reassembly Valve Guide Exhaust Valve Tappet Valve Spring Intake Valve Rocker Valve seals Valve spring Retainer Rocker arm Push Stud Lock Nut Rocker Arm Pivot PH3100Ri SM Revision 03-03-2014r1...

  • Page 61: Inspection

    Service limit 39.1mm (1.54”) 37.5mm (1.48”) ● Valve seat width Standard Service limit 0.8mm (0.03”) 1.8mm (0.07”) ● Valve stem outer diameter Standard Service limit 6.465-6.480mm (0.2545”-0.2551”) 6.40mm (0.2520”) Inlet valve 6.455-6.470mm (0.2541”-0.2547”) 6.40mm (0.2520”) Exhaust valve PH3100Ri SM Revision 03-03-2014r1...

  • Page 62: Crankshaft / Piston

    13. Crankshaft / Piston 13.1 Crankshaft, camshaft and piston Piston and Rod Front Engine Seal Front Crankshaft Lifters Bearing Low Oil Sensor Crankshaft Rod Bolts Lower Rod Cap PH3100Ri SM Revision 03-03-2014r1...

  • Page 63: Alignment Of Timing Marks

    13.2 Alignment of timing marks Use marks to align camshaft gear and timing gear during installation. Timing Marks Cam Gear Crankshaft Gear PH3100Ri SM Revision 03-03-2014r1...

  • Page 64: Camshaft Inspection

    13.3 Camshaft Inspection ● Height of camshaft Standard Service limit 31.700-31.780mm (1.2480”-1.2512”) 31.0mm (1.2205”) Intake/Exhaust PH3100Ri SM Revision 03-03-2014r1...

  • Page 65: Piston / Connection Rod

    ? ? ? ? ( ? ? ● Make sure the piston rings are free to move after installation. ? ? ? ? ( ? ? ring ● Stagger each piston ring gap 120°from each of the other rings. Oil ring PH3100Ri SM Revision 03-03-2014r1...
  • Page 66 ● Cylinder inner diameter Standard Service limit 77.000-77.020mm (3.0315”-3.0323”) 77.105mm (3.0356”) ● Piston skirt outer diameter Standard Service limit 76.960-76.980mm (3.0299”-3.0307”) 76.85mm (3.0256”) 10mm ● Side clearance of piston ring Standard Service limit 0.02-0.06mm (0.001”-0.002”) 0.15mm (0.006”) PH3100Ri SM Revision 03-03-2014r1...
  • Page 67 0.15-0.25mm (0.006”-0.010”). 1.0mm (0.040”) ● Piston ring height Standard Service limit The 1 ring 1.97-1.99mm (0.0776”-0.0783”) 1.87mm (0.0736”) The 2 ring 1.97-1.99mm (0.0776”-0.0783”) 1.87mm (0.0736”) ● Piston pin outer diameter Standard Service limit 17.994-18.000mm (0.7084”-0.7087”) 17.95mm (0.7067”) PH3100Ri SM Revision 03-03-2014r1...
  • Page 68 ● Piston pin hole inner diameter Standard Service limit 18.002-18.008mm (0.7087”-0.7090”) 18.05mm (0.7106”) ● Connection rod small end inner diameter Standard Service limit 18.006-18.017mm (0.7089”-0.7093”) 18.08mm (0.7118”) ● Connection rod big end inner diameter Standard Service limit 33.020-33.033mm (1.3000”-1.3005”) 33.09mm (1.303”) PH3100Ri SM Revision 03-03-2014r1...
  • Page 69 ● Crankshaft neck outer diameter Standard Service limit 32.90mm (1.295”) 32.967-32.980mm (1.2979”-1.2984”) ● Connection rod big end side clearance Standard Service limit 0.1-0.4mm (0.004”-0.016”) 0.8mm (0.030”) PH3100Ri SM Revision 03-03-2014r1...

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