Service Manual - Powerhouse Generators
Contents
1. IGNITION ER A SWITCH REMOTE CONTROLLER RECEIVER MOTOR YELLON GREEN 140 BLACK 107 recreo srs WHITE a em WHITE Bi a BLACK T ORANGE a y PINK 5 208 OUTPUT s HE ne D airs iata J 2010 04 20 2 Service information 2 1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the engine Any error or oversight made by the technician while servicing can easily result in faulty operation damage to the engine or injury to the operator A Warning Improper servicing can cause an unsafe condition that can lead to serious injury or death Follow the procedures and precautions in this shop manual carefully Some of the most important precautions are given below However we cannot warn you of every conceivable hazard that can arise in performing maintenance or repairs Only you can decide whether you should perform a given task Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed Follow the procedures and precautions in this shop manual carefully 2 2 Important safety precautions Be sure you have a clear understanding of2. 65 PH3100Ri SM Revision 03 03 2014r1 O 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 O Side clearance of piston ring Standard Service limit 0 02 0 06mm 0 001 0 002 0 15mm 0 006 66 PH3100Ri SM Revision 03 03 2014r1 O Piston ring end clearance Locate the piston ring into cylinder with piston top and measure the piston end clearance Standard Service limit 0 15 0 25mm 0 006 0 010 1 0mm 0 040 O 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 67 PH3100Ri SM Revision 03 03 2014r1 O Piston pin hole inner diameter Standard Service limit 18 002 18 008mm 0 7087 0 7090 18 05mm 0 7106 NI N N x X N N J EN J LLL Connection rod small end inner diameter Standard Service limit 18 006 18 017mm 0 7089 0 7093 18 08mm 0 7118 O Connection rod big end inner diameter Standard
3. a0z00Qoiro0 69205 1 24 Breatherhose 20713001000 1 25 voecovergaster fsosoanosrooo exe 26 Spark plug F7RTC 09080151 69537 i 27 Intake mounting studs 28 Valve tappet 69267 29 Intake valve 69268 30 Exhaust valve 69269 31 Guide plate 69558 32 Valve adjustment screw 69560 33 Valve spring 69561 34 Rockerarm 69562 35 Rocker arm shaft 36 Exhaust valve retainer 69563 37 Exhaust valve cap 1 38 Intake valve spring cup 69564 39 Exhaust valve sping cup 2 69568 Valve clearance adjusting nut 69569 41 Camshaftassembly 42 Flywheel Nut 3 69571 44 45 Crankshaft assembly 177010400200 46 45 Crankshaft big gear 15207N08F000 Crankshaft small gear 15237NO08F000 57 PH3100Ri SM Revision 03 03 2014r1 uy p ojojo lg g D a 2 12 8 2 E S 5 he Si w S o a 3 gt D e Ir hb a D lt 177 Engine Parts List N Description ERP NO Stk No Qty 0 47 48 Piston w rings 15100NO8FF10 1 49 52 piston pin 15105NO8F000 f piston pin clip 15106K07F000 PF Connecting rod cover 15132NO08F000 Connecting rod bolt 15133Q01F930 NEN 7 58 PH3100Ri SM Revision 03 03 2014r1 12 Valve cover Rocker arm 12 1 Cylinder Head Removal Caution E Drain all gasoline from the fuel tank before disassembly BI Keep the unit away from all heat flame and sparks Disconnect and remove the battery Remove the front and rear end panels a
4. POWERHOUSE PH3100RI Digital Inverter Generator SHOP MANUAL Coast Distribution System March 2014 PREFACE This manual covers the construction function and servicing procedure of the POWERHOUSE PH3100Ri generator certificated by CARB 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 Coast Distribution Systems Inc reserves the right to make changes without incurring any obligation whatsoever No part of this publication may be reproduced without written permission 2 PH3100Ri SM Revision 03 03 2014r1 CONTENTS 1 SPECIFICATIONS PREFACE sich tee A de REINER IHRER RR IHR IR RR E 2 CONTENTS 2 etoile sonare te pt eir tenet rei epe rates 3 T SPECIFICATIONS 22 22 22 20 ss near c EGRE e Pp ann e rese a p ee Peta ra 6 1 1 SPECIFIGATIONS 2 04 fate hana ante ee o ee a a Rie e Gi t e o eaa aras 6 1 2 CHARACTERISTICS x DH Rp ee te Hae Rb e sn eee etes jl 1 3 Wiring Diagram w o electric choke solenoid sess enne rennen 9 1 4 Wiring Diagram with electric choke solenoid beginning with S N 100602380706001 sss 10 2 Service INTOTMAUON n u TR 11 2 1 The importance of proper servicing ueescesesnesnersersunsnennennonnnennennennonnnennennonnnsnnesnennonsnsnnennennensn
5. o BLACK 144 YELLOWGREEN 14 RESET BUTTON GRAY 204 0 7 o WHITE 208 1 BLACK 14 VOLTAGE N BLUE 168 20o 4ramzmo YELLOW GREEN 14 BLACK BLUE WHITE 208 BROV WHITE 208 22 ECONOMY f WHITE ORANGE 204 PINK RED 208 ORANGE BROWN 208 A ia WHITE BLUE 208 C e D 6 204 OVERLOAD El BLACK 204 y CURRENT H BLACK i16 A T AC 90920 oto xH HOUR METER Woa GRAY 10 x DC BREAKER pum DC SOCKET BFP RED RED CONTROLLER BFP RED BLACK 20 SOLENOID BLACK 20 REGULATOR RED RED ne eer ETT nz mi SR Ren auch ie T i WHITE WHITE i WHITE WHITE RED SLACK 164 BLUE 164 s RED BLACK 16 GROUNDING O ais d BLACK 107 4 i2 eue 160 GREEN BLACK ar RED 16 WHITE 2 EZ Mes CHARGE j THE BATTERY E STOP RED 19 A L Y WHITE en ON RELAY BATTERY OIL SENSOR
6. the voltage regulator and measure Abnormal Check the wiring harness or the resistance replace the stator Resistance 0 045 0 0700 Normal Replace the voltage regulator DC Battery To the Charge Voltage Windings Regulator from Stator 24 PH3100Ri SM Revision 03 03 2014r1 1 Battery charge voltage from the voltage regulator at the starter battery should be 12 0 to 14 5 volt DC Battery charge 2 The voltage to the control panel should measure 13 to 15 volts DC Voltage Regulator V Battery charge Wire to Starter Solenoid Harness Plug to Circuit Breaker ti EU and DC t Receptacle B To Ignition f Switch Chassis Ground Starter Terminal Solenoid Spade Harness Plug to Terminal DC Stator Charge Windings 25 PH3100Ri SM Revision 03 03 2014r1 3 14 No electric start Measure battery voltage APNEA Charge battery Normal 00 Abnormal Check the ignition switch Replace ignition switch Normal Check the ground between the relay Abnormal Repair ground engine and control panel Normal Abnormal Check the starter relay gt Replace the starter relay Normal Abnormal Check the starter motor Replace the starter motor Normal Check repair or change main harness wires Motor Eh Cable from Starter Solenoid Battery Terminal Starter motor Terminal Start Wire from Ignition Switch Starter Solenoid Chassis Ground 26 PH3100Ri SM Revision
7. Service limit 33 020 33 033mm 1 3000 1 3005 33 09mm 1 303 68 PH3100Ri SM Revision 03 03 2014r1 O Crankshaft neck outer diameter Standard Service limit 32 967 32 980mm 1 2979 1 2984 32 90mm 1 295 O Connection rod big end side clearance Standard Service limit 0 1 0 4mm 0 004 0 016 0 8mm 0 030 69 PH3100Ri SM Revision 03 03 2014r1
8. arm adjustment screw and loosen the locknut b 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 Replace the rubber valve cover seal 6 Install the removed parts in the reverse order of removal a 38 PH3100Ri SM Revision 03 03 2014r1 5 Muffler system Caution E Muffler removal installation must be performed with the engine cold E Drain all gasoline from the fuel tank before disassembly E Keep the unit away from all heat flame and sparks 5 1 Spark arrestor A CAUTION e f the generator has been running the muffler will be very hot Allow it to cool before proceeding N NOTE The spark arrester must be serviced every 100 hours to maintain its efficiency 1 Remove the exhaust grill to access the spark arrestor Remove the clamp holding the spark arrester to the muffler Clean the spark arrestor with a stiff wire brush Replace the spark arrestor ifthe wire mesh is perforated or torn Reinstall the spark arrester upon Reinstall the exhaust grill Spark Arrestor Clamp A Exhaust Grill 39 PH3100Ri SM Revision 03 03 2014r1 5 2 Muffler Disassembly Reassembly 1 Disconnect battery Remove the front and rear end panel the side panels and the fuel tank cover Remove upper frame with fuel tank as one assembly Remove the muff
9. clearance 0 6 0 8mm 0 024 0 032 y0 Feeler 53 PH3100Ri SM Revision 03 03 2014r1 10 Stator and Rotor disassembly reassembly 10 1 Stator Inspection 1 Disconnect and remove the battery Remove the front panel Remove the inverter Locate the 6 pin connector at the inverter and unplug it ak YN Locate the two pin connector from the stator and unplug it from the voltage regulator DC charging windings Measure the resistance between the two blue terminals at the 2 pin connector Blue Blue Resistance 0 045 0 070 Q Sub windings Measure the resistance between the two sub winding terminals at the 6 pin connector White White Resistance 0 10 0 16 Q Main windings Measure the resistance between each of the main winding terminals at the 6 pin connector Black Black Black 0 25 0 35 O Resistance gt 2 Pin Connector from Stator to Voltage Regulator j 6 Pin Connector from s Stator to Inverter 54 PH3100Ri SM Revision 03 03 2014r1 10 2 Stator Removal Reassembly Caution E Drain all gasoline from the fuel tank before disassembly E Keep the unit away from all heat flame and sparks Disconnect and remove the battery Remove the front and rear end panels and the left and right side panels Remove the upper frame and the fuel tank as an assembly Remove the inverter Disconnect all wires from the st
10. properly Set in fully close or half close position Carburetor faulty Inspect disassemble and clean 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 15 PH3100Ri SM Revision 03 03 2014r1 3 2 Hard starting No fuel Check the fuel level gt Add fuel and restart the engine Sufficient fuel No fuel at Loosen the drain screw and carburetor Check fuel filter and fuel valve check whether fuel reached the carburetor Good spark Remove the spark plug and Dry Check fuel lines and carburetor for check for wet or fouled any blockage or a stuck float electrode Clean the electrode and restart Wet y taking care that the choke is not closed too much If flooding is severe check the carburetor float Perform the ignition system troubleshooting Low oylinder Install a compression gauge in compression 1 Check the valve clearance the spark plug hole and check 2 Check for carbon deposits in No spark or weak spark Install the spark plug and ground the electrode Check the spark Good spark the cylinder compression by pulling the recoil starter rope several times Normal compression Install the spark plug securely Restart the engine according to the starting procedure the combustio
11. thee bae Re e et ER ee ra e dads eet eias leone 40 6 Carburetor nnomi nein RP OA A ek 41 6 1 Disassembly Installation of Carburetor sionin riiin i a a E a i 41 6 2 Disassembly Installation of Step 10060 seesseeeeeeeeeeessesersesesseseseesesesesessestreeseseeseseeeseseestneeseseesesesresesesereeseseeseses 42 6 3 Ep MOL INSPECHON ld RR iaa 42 6 4 Fuel Shutoff solenoide In 43 6 5 Backfire controller BFP 6 6 Automatic choke assembly essent 43 6 6 Automatic choke assembly eite iret eie steh e EE Fidei gt eli d E gua Fed pr EGER Pe ee di 44 6 7 High Altitude jet installation a re tet e Re er re test et o los ex bebe he Lege repr e DR pta tee e hang 45 FG 46 71 Disassembl ys Installation afe m eta etae beta st anten ur abe rete t ntis 46 SO Outer Senerator HOUSING uk Utere er Ce hore COR Ue DOR ORO UR DAS EDER FE Gre CORTE DISPO IER eiie s 47 8 1 Disassembly Install ti n 2t nter eet rette a eR Het Re orte Eo arietes 47 9 Recoil starter Disassembly Reassembly sess nne etre rn non e eA EE Tias 48 9 TInlet Fan Cover zie es Rede td eme ene ed e decem ee RR sis 49 9 2 Starter THOtOE riori d ero ee em m ee mh e eh da EO gen p dnt EY ede dis 50 A RR 51 9 4 Tenition coil Inspection id ee et EE ERU a DS S CEP RD Ee ae SER e Rea e P ense toes 52 9 5 Ignition coibAdjustment Replacement tene Do Pete ees re eee eli dente 53 10 Stator and Rotor disasse
12. 03 03 2014r1 3 15 Engine will not shut off with ignition key remote or stop button For safety we recommend turning off the fuel valve instead of pulling off the spark plug wire What to check for 1 Turn on the fuel valve and restart the engine 2 Using a volt ohm meter check the battery charge receptacle There should be between 12 and 14 volts DC If no voltage is present check all connections to and from the voltage regulator 3 Check to make sure that there is a good ground between the voltage regulator ground wire engine and control panel A bad ground will prevent the unit from shutting down properly 4 Locate and unplug the two blue wires between the stator and voltage regulator With the engine running the voltage from the stator must be 12 20VAC If no voltage is present the stator is defective If voltage is present replace the voltage regulator 5 If voltage is present at the control panel make sure that the remote switch on the control panel is in the off position 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 Voltage Regulator i Battery charge Wire to Starter Solenoid To Ignition Chassis E Switch Ground Starter Solenoid Terminal Spade Terminal Harness Plug to Circuit Breaker and DC Receptacle Harness Plug to DC Stator Charge Windings 27 PH3100Ri SM Revision
13. 03 03 2014r1 3 16 Engine will not start or stop with remote Does the red indicator light on the remote come on when either the start or stop buttons are pushed Is there continuity at the remote rocker switch when it is in the on position Yes Replace the transmitter battery No Replace rocker switch With the engine running disconnect the Check ground wire between the red wire from the battery and measure Pues b gd ds and the voltage between the red wire and Chassis nece voltage DENNSEN chassis ground There should be 12 15 ground wire from voltage regulator VDC coming from the regulator and red battery cable No voltage Replace Voltage regulator Abnormal Repair or replace faulty connections Check 6 pin connection at the remote receiver Replace the remote transmitters and receiver 28 PH3100Ri SM Revision 03 03 2014r1 3 17 Engine will struggle when shut off with key or remote but keeps running rough For safety we recommend turning off the fuel valve instead of pulling off the spark plug wire What to check for 1 Remove the end panel and locate the BFP Back Fire Controller 2 Check all connections and repair or correct as needed 3 Disconnect the green black wire from the fuel shut off solenoid 4 Turn on the fuel valve and restart the engine 5 Using a volt ohm meter connect the positive lead to the green black connector from the BFP Back Fire Controller and the ground lead to the e
14. 9 0 7093 0 7118 rod Bia end 1 D 33 020 33 033mm 33 09mm 9 1 3000 1 3005 1 303 32 967 32 980mm 32 90mm Crankshaft Crank pin O D 1 2979 1 2984 1 295 0 10 0 02mm Valve 0 004 001 clearance 0 15 0 02mm 0 006 001 00000 6 465 6 480mm 6 40mm Valves N 0 2545 0 2551 0 2520 6 455 6 470mm 6 40mm 0 2541 0 2547 0 2520 6 500 6 530mm 6 56mm Az 0 2559 0 2571 0 25837 0 8mm 0 03 1 8mm 0 07 Valve spring Free length 39 1mm 1 54 37 5mm 1 487 31 700 31 780mm 31 0mm heel i Cam height 1 2480 1 2512 1 2205 ET 032 Carburetor Float height Pilot screw opening Fixed A 0 024 0 028 2 mir m Second sds 5 598 14 PH3100Ri SM Revision 03 03 2014r1 2 6 Motor _ Pat itm Wirecolo Standard Q DC winding blue blue 0 045 0 070 Sub winding 0 100 0 160 black black black 0 250 0 350 2 7 Torque values T Tightening torque tm Speer ure Nm Connection rod bolt M8x40 21 4 23 6 29 32 Spark plug M12x1x13 8 9 11 0 12 15 M8x35 20 7 22 9 28 31 M6 Blot nut 5 9 7 4 8068094909108 M8 Bolt nut 14 8 17 0 18 22 M10 Bolt nut 40 6 44 3 55 60 Note Use standard torque values for fasteners that are not listed in this table Flywheel nut M16x1 5 66 4 73 8 90 100 M5 Bolt nut 4 4 5 9 3 Trouble shooting 3 1 General symptoms and possible causes Throttle not opening
15. Abnormal 2 Check the carbon deposit in Measure the cylinder compression combustion chamber 3 Check the piston piston ring and cylinder for damage Abnormal 20 PH3100Ri SM Revision 03 03 2014r1 3 7 Engine speed can t increase or is unstable choke is in the correct position Not blocked Not blocked Inspect spark arrestor for carbon build up Blocked Remove and clean carbon deposits Not blocked Remove the spark plug and check the Abnormal Clear electrode adjust electrode clearance for carbon deposit clearance or replace the spark Normal Check the carburetor and nozzle for Blocked blockage Disassemble and clear No blockage Abnormal j Check the carburetor gasket for leakage Tighten carburetor bolts or replace gasket as required Normal 1 Check the valve clearance i Al iti Measure the cylinder compression bnormal 2 Check the carbon deposit in the combustion chamber 3 Check the piston piston ring and cylinder for damage Perform the throttle control system test 3 8 Engine speed too high or too low Abnormal Perform the generator trouble Dace ie AS OU IUE shooting following the instruction of No or low AC output Normal Abnormal 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 har
16. all basic shop safety practices and that you are wearing appropriate clothing and safety equipment When performing maintenance or repairs be especially careful of the following A warning i Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards a Be careful to avoid carbon monoxide poisoning from engine exhaust b Make sure there is adequate ventilation whenever you run the engine c Be careful to avoid burns from hot engine parts and hot exhaust d Letthe engine cool before you touch it e Be careful to avoid injury from moving parts Do not run the engine unless the service manual instructs you to do so When the engine is running keep your hands fingers and clothing away from moving parts 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 11 PH3100Ri SM Revision 03 03 2014r1 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 Always install new gaskets O rings etc when reassemblin
17. and must be supplied before any work can be done The engine serial number can be found stamped on the engine block above the oil dipstick It is visible when the engine oil access cover is removed Serial Number 2 5 Engine maintenance standards Maximum speed without load 3600 100rpm rum ae 77 000 77 020mm 77 105mm y Sleeve 1 D 3 0315 3 0323 3 0356 76 960 76 980mm 76 85mm nen Sein 3 0299 3 0307 3 0256 DU 18 002 18 008mm 18 05mm 0 7087 0 07090 0 7106 Piston pin 17 994 17 000mm 17 95mm 0900 0 7084 0 7087 0 7067 1 97 1 99mm 1 87mm dica 0 0776 0 0783 0 0736 Ring side clearance 902 006 0 15mm Piston rin st rin E 0 001 0 002 0 006 i i Ring end clearance Da Aom 1 0mm E 0 006 0 010 0 04 j 3 40 3 60mm 3 20mm 06 13 PH3100Ri SM Revision 03 03 2014r1 2 5 nn maintenance standards e _ Standard 1 97 1 99mm 1 87mm TEQUE 0 0776 0 0783 0 0736 Ring side clearance 0 02 0 06mm 0 15mm 2nd rin 0 001 0 002 0 006 i Ring end clearance 0 15 0 25mm 1 0mm i 0 006 0 010 0 04 3 40 3 60mm 3 20mm Fon ng 0 134 0 142 0 126 continued SA Sen nn iid 0 134 0 142 0 126 Ring side clearance 0 03 0 18mm 0 24mm Oil rin 0 001 0 007 0 009 i Ring end clearance 0 20 0 50mm 1 0mm 9 0 008 0 020 0 04 7 3 2 7mm 2 2mm ma ID end I D 18 os 1a OT Am 18 08mm Connecting 0 708
18. arting system Remote Electric amp Recoil Stopping system Primary circuit ground Automotive unleaded gasoline Alternator Alternator type Multi pole rotation type Alternator structure Self ventilation drip proof type Self excitation Magnet type Single phase Rotating direction Clockwise Viewed from the generator Frequency regulation AC DC AC conversion Inverter type 1 2 CHARACTERISTICS Voltage variation rate Momentary 10 max Average 1 5 max Average time 3 sec max Voltage stability Frequency variation rate Momentary 1 max Average 1 max Average time 1 sec max Frequency stability Insulation resistance 10MOmin AC circuit protector 20A and 30A 120V 7 PH3100Ri SM Revision 03 03 2014r1 DC circuit protector 10A Fuel tank capacity 4 4 gal 16 6L Continuous running time at rated load at load Noise level Zero load to full load 56 65 dB 23 7m 7 6 hours 17 8 hours 8 PH3100Ri SM Revision 03 03 2014r1 1 3 Wiring Diagram w o electric choke solenoid z YO S lt Za S X INVERTER ASSEMBLY Owuwzwum omo 2009 11 17 1 4 Wiring Diagram with electric choke solenoid beginning with S N 100602380706001 PH3100Ri WIRING DIAGRAM CONTROL PANEL INVERTER ASSEMBLY AC SOCKETS BLACK 124 AC BREAKERS BLACK 12 eray WHITE 304 204 WHITE 204 PINK E fo H P WHITE 20 BLACK 204
19. ator assembly Disconnect the starter motor wire and all ground wires Disconnect the BFP controller from the ignition coil and carburetor Remove 4 nuts from the engine mounting bolts 2 on each side and lift the engine assembly off of the base pan 9 Remove the ignition coil starter cup and fan ox mS m5 10 Remove the M16 cap nut from the crankshaft 11 Attach the appropriate puller to the rotor using 3 M6 bolts grade 8 8 or better and remove the rotor 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 Intake fan Cable Retainer Clip and Bolt 55 PH3100Ri SM Revision 03 03 2014r1 11 Exploded engine view vc ce vl 9c GL ZL 9L EZ 8 Co A gt o Co Cc Co Oo Co vs SS Er Zr gz DE 66 LE Ze vv OV CIS v 56 PH3100Ri SM Revision 03 03 2014r1 177 Engine Parts List NO Description ERP NO Stk No Qty 177010010300 Crankcase end plate Engine cover gasket 69258 69259 Dipstick gasket 69260 Drain bolt gasket Guide pin 2 10 Oil seal 30x46x8 69261 11 Low oil sensor 69262 12 Main bearing 13 M8x35 hex bolt 14 Cylinder head bolt 15 Valve cover bolt 16 69263 17 _ Spacer 18 Cylinder bottom cover plate 19 Exhaust gasket 69472 20 Carburetor mounting block 69546 21 Mounting block stud 22 Cylinder head 69264 23 Valve cover
20. connecting the connector Secure the harness clips in the specified locations on the frame and clamp the wire harnesses Clamp the wire harnesses securely so that they do not interfere with rotating parts moving parts or hot parts Route and connect the wire harnesses as shown in the service manual Be sure that the harnesses are not loose twisted or pulled tight Route the wire harnesses properly so that they do not contact with shape edges or corners or the end of any bolts or screws If a wire harness contacts the end of any bolts or screws or sharp edges or corners protect that part of the harness with a tube or by wrapping with an insulating tape If the wire harness has a grommet install the grommet securely Take care not to pinch the wire harnesses during installation of a part If a wire harness has the damaged insulation repair by winding with the electrician s insulating tape Before using the tester carefully read the manufacturer s instructions and follow the instructions in this Service Manual Be sure that the test unit s battery is fully charged and verify that the unit is operating correctly before you begin testing 12 PH3100Ri SM Revision 03 03 2014r1 2 4 Serial number location The generator s engine serial number identifies your particular unit and is required when ordering parts and accessories The generator serial number is also used by your dealer and Coast Distribution for warranty administration
21. eck ignition coil air gap Readjust air gap Normal Inspect or replace wire harness 19 PH3100Ri SM Revision 03 03 2014r1 3 5 Engine oil level is low but engine does not stop Drain out oil completely disconnect the oil Check and repair all wire sensor wire harness and check the No continuity connections Replace the continuity between black wire and the oil level alarm chassis ground Continuity Ground the white lead from the indicator No continuity Repair or replace the wire module to the engine block to ensure that harnesses the engine will stop when the low oil alarm lamp is lit Continuity Indicator module fault replace the module 3 6 Engine stops running Throttle is in the correct position Oil sensor Check the oil level and oil sensor Fill oil reservoir to the proper level and restart the engine Sutficient oil Check fuel level Bone Add fuel and restart the engine Sufficient fuel Check the fuel valve and fuel filter for Blocked Clear the fuel valve and blockage replace the fuel filter Not blocked d Blocked Clear or replace the fuel supply hose Not blocked Normal Check the carburetor gasket for leakage Abnormal Tighten carburetor bolts or replace gasket as required Normal Per ieai ee Abnormal Refer to step motor inspection een section in service manual Check ignition coil Readjust the coil clearance Normal 1 Check the valve clearance l
22. en nennen enne nre nne nnns 23 3 12 No DC output at battery charge receptacle essent nennen nnne nne nnne 24 3 13 Battery will not Charge iii HEP ert nep dante eee Hte repe Hi ae ah ins ici 24 3 14 No electric Start Sev Bla dept oie e ine de De nee idis 26 2 15 Engine will not shut off with ignition key remote or stop button u uueesessessnesnessersuesnennennnnnnennennonnnnnnennenenannn 27 3 16 Engine will not start or stop with remote nennen eenretnen enne trennen enne ne enne 28 3 17 Engine will struggle when shut off with key or remote but keeps running rough eese 29 3 18 Engine willstart and then Shut down 4 5 eerte ep eter Pn en et P RH nens 30 4 MaMe ANCE P EC 31 4 1 Maintenance sched le 2 u te ala als lieder ee den ehe ie dre e ete erint 31 4 2 Checking theil level eii RE eee ie e ie eem ome HO 32 4 3 Cham in oil 5 ieu ale eu eise tab tetebiae aepo dene 33 44 Checking the low Oil SENSOR seen NN 34 4 5 Aur Cleaner deno e PP gens I ER dU RR e o d repe ar qe re E ri I 35 3 PH3100Ri SM Revision 03 03 2014r1 AOS Dark PUE a A RD E CH totis e ro RLUUB Oa Den E PAG Loon oderunt Forever 36 NINAS A RRA 37 4 8 Evaporation Control SyStem nette better neither teet quete segete AA 37 5 M ller System ace eee Ree eene iia 39 SVS Park arrestor site err t e ri cte d ect m pid re ed e pde d dea 39 SL MUER zai ir iia eet Re le Do et Eno ub an oats
23. eplace as necessary Notes 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 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 31 PH3100Ri SM Revision 03 03 2014r1 4 2 Checking the oil level Stop the engine and check the oil level be sure to put the engine on a flat surface when checking 1 Loosen the screw on the engine oil access cover and remove the cover 2 Remove the oil filler cap and check for the oil level 3 Ifthe oil level is low add oil until it reaches the edge of the oil filler port Upper level Y U Limit N pper Limi Lower Limit uet Lower level 32 PH3100Ri SM Revision 03 03 2014r1 4 3 Changing oil Drain the oil while the engine is still warm to assure rapid and complete draining y CAUTION B Make sure to turn the engine switch and fuel lever OFF before draining Loosen the screw on the engine oil access cover and remove the cover Remove the oil filler cap Install the oil drain pipe Drain dirty oil into a container Allow enough time for the oil to drain completely Refill with the reco
24. f the outlet terminals of the step motor Pin 1 blue Pin 2 white 50 550 Pin 3 red Pin 4 black 50 550 Resistance value 2 Replace the step motor if the resistance exceeds the standard value 42 PH3100Ri SM Revision 03 03 2014r1 6 4 Fuel shutoff solenoid Measure the resistance of fuel shutoff valve between the two leads Resistance value 7 90 Replace the electromagnetic valve if the resistance exceeds the standard value Measure resistance between these Leads 6 5 Backfire controller BFP Green Black Connects to the Fuel Shutoff Solenoid Red Black Connects to the DC Power Supply from Voltage Regulator ww Connects to Mus Connects to the Ignition the Ignition Switch Coil 43 PH3100Ri SM Revision 03 03 2014r1 6 6 Automatic choke assembly 1 The automatic choke consists of the backpressure check valve and the vacuum pot 2 ltems to check if the automatic choke fails to operate a b c Check all vacuum hoses for cracks or damage replace as necessary Check the backpressure check valve for leaks or a defective diaphragm Check all choke linkage to insure that it operates smoothly and that the choke closes and opens fully Check the vacuum pot for leaks With the lever depressed pinch off or block the end of the hose The plunger should stay in the retracted position as long as the hose is pinched or closed off Hose to Intake Manifold bd Vacuum P
25. g 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 Clean parts in cleaning solvent upon disassembly Lubricate any sliding surfaces before reassembly After reassembly check all parts for proper installation and operation Many screws used in this machine are self tapping Be aware that cross threading or over tightening these screws will strip the threads and damage the hole Use only metric tools when servicing this engine Metric bolts nuts and screws are not interchangeable with non metric fasteners The use of incorrect tools and fasteners will damage the engine E Electric precautions 1 Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect Check the connector terminals for bent pins excessive stretching missing terminals or other abnormalities before connecting the connector To connect insert the connector completely into the receptacle If the connector is a locking type be sure that it is locked securely Check the connector cover for cracks or other damage and make sure the connector female terminal fits snugly into the connector Then connect the connector securely Check the connector terminal for rust Remove any rust using an emery paper or equivalent material before
26. ground wire and pull the recoil starter rope to check the spark plug A E xu POET Ground PHB IOORG Wire ta E SA ll ne J L Spark Plug m S JAM UNA E EE J S n SI O Spark Plug Spark Plug Boot Wire 18 PH3100Ri SM Revision 03 03 2014r1 Measure the spark plug gap and perform the spark plug test Standard clearance 0 6 0 7mm 0 024 0 028 No spark Perform the spark test again using a Good spark new spark plug No spark Replace the spark plug Remove the control panel Perform the Good spark spark test using a new indicator module Replace the module No spark Good spark Check the ignition switch Replace the ignition switch No spark Good spark Disconnect the low oil alarm and perform spark test Replace the low oil alarm No spark Abnormal Check the resistance of stator ignition winding Replace the stator Normal Check the ignition coil resistance and Abnormal high pressure cable high pressure Replace the ignition coil insulation cap Abnormal Check the BFP controller gt Replace the BFP controller Normal Abnormal Ch
27. haft camshaft and piston Front Crankshaft Lifters Bearing Low Oil Sensor Crankshaft _ 4 Rod Bolts Lower Rod Cap 62 PH3100Ri SM Revision 03 03 2014r1 13 2 Alignment of timing marks Use marks to align camshaft gear and timing gear during installation Timing Marks Cam Gear 63 PH3100Ri SM Revision 03 03 2014r1 13 3 Camshaft Inspection O Height of camshaft Standard Service limit Intake Exhaust 31 700 31 780mm 1 2480 1 2512 31 0mm 1 2205 64 PH3100Ri SM Revision 03 03 2014r1 13 4 Piston Connection rod Manufacturers Label 1st ring 2nd ring Oil ring Piston N X Piston pin Installation set the front end in the piston groove and clamp the other end Install the ring clip by revolving Make sure that the gap of the ring clip is not in line with the groove in the piston pin hole O Ser en Clip ring Piston pin clip ring Connection rod Installation The larger side of the connection rod must be aligned with the A label on the piston Assembly of piston rings Caution Make sure the rings are installed with the manufacturer s label up Make sure the 1st ring and 2nd ring are not interchanged 1 ring Make sure the piston rings are free to move after installation drca 2 ring Stagger each piston ring gap 120 from each of the other rings eed Oil ring
28. ile running 6 Pin Stator Connector 6 Pin Stator Receptacle White Sub Windings 3 amp 6 Black Phase Wires 1 2 amp 4 1 Unplug the connector from the inverter and start the engine check voltage between pins 1 amp 4 between pins 2 amp 4 and between pins 1 amp 2 Note the engine will be running at a high RPM 2 They should be approximately 300vac at each test with the engine running at high speed If one or more of the three tests fail the problem is either a damaged wire harness or a defective alternator 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 23 PH3100Ri SM Revision 03 03 2014r1 3 12 No DC output at battery charge receptacle led d 12 Abnormal Perform the throttle control system s the engine speed normal test Normal ei Abnormal Check the DC circuit breaker m Reset DC circuit breaker Normal Abnormal Check the wire harness and all Check the DC output connections to and from the voltage regulator Normal Abnormal Check battery charge cables Replace Battery charge cables 3 13 Battery will not charge Clean and tighten all battery Abnormal Normal A Check the DC output at the battery bnorma Check all wire connections of the voltage regulator Normal Unplug the DC charge windings from
29. ler cover o gt 0 Remove the muffler Carefully note the various length bolts and spacers during removal and reassembly Upper Frame and Fuel Tank el ee CAP uti Muffler Cover Bolts Gasket Long li A Z J Y M8x170 M8x150 Secondary Air valve 40 PH3100Ri SM Revision 03 03 2014r1 6 Carburetor 6 1 Disassembly Installation of Carburetor Caution B Drain all gasoline from the fuel tank and the carburetor before disassembly E Keep the unit away from all heat flame and sparks Disconnect the battery Remove the front and rear end panels and left side panel Remove the inverter Remove the air filter cartridge and filter Remove air filter cover screws Remove flange nuts retainer plate and air box Remove the carburetor and choke as an assembly being careful not to pull on the step motor wires Sea Pe SS x Remote Receiver m Air Filter Cover Automatic Choke 4 Check Valve Assembly j i Samui Carburetor 41 PH3100Ri SM Revision 03 03 2014r1 6 2 Disassembly Installation of Step motor e Disassembly and installation of step motor 1 Unplug the step motor plug from the inverter 2 Remove the step motor mounting bracket being careful not to loosen the fork spring 3 Remove the throttle fork from the step motor shaft and remove the step motor screws iS Step Motor Fork Spring 6 3 Step motor inspection 1 Measure the resistance o
30. mbly reassembly eese te enne eerte nne 54 101 StatorInspection 2 222 22222 et o ten eer mete ene e da eim nb ei e dee ehe inten 54 10 2 Stator Remoyal Reassembly 52 2 tete e re ee t eee i eth e eins 55 1T Exploded engine views aan RR RE b edm im endete 56 12 Valye cover ROCKGE r iue iter deti NA 59 12 1 Cylinder Head Removal 2 areas e Re ete een e a HI UEM ents tu HP ERR guebeeveguussanpeedae 59 12 2 Cylinder Head Disassembly and Reassembly essere nennen eene 60 12 3 Inspection uode tete ir ar DE NA ASE AA A nee enden 61 13 gt Crankshaft Piston 2 2 2 2280 EN 62 13 1 Crankshaft camshaft and piston eit snensessnackennsencineassnnchsansnndunssken 62 13 2 Ahignmentof timing marks 5er rien A 63 13 3 Camshaft Inspection eth nte te n ee ae ten ene e ebene 64 13 4 Piston Connection tod iit tte t tee t eter e e e ea 65 4 PH3100Ri SM Revision 03 03 2014r1 PH3100Ri SM Revision 03 03 2014r1 1 SPECIFICATIONS 1 1 SPECIFICATIONS Dimensions and weights PH3100Ri Overall Length 24 in 610mm Overall Width 18 in 457mm Overall Height 18 3 in 464mm Net Weight 129 lbs 59 kg Engine 177 27000 Maxmumhorepower 68 gt o Spark plug Semi dry type Lubrication system 6 PH3100Ri SM Revision 03 03 2014r1 SAE 10W 30 15W 30 SF SG grade or greater for Lube oil temps above 32 F SAE 0W 30 0W 40 for temps below 32 F Oil capacity 35 oz 1 0 L St
31. mmended oil and check the oil level NP O wm 2 Reinstall the access cover and tighten the screw securely Engine oil capacity 35 oz 1 0L NS Upper Limit Upper level 29 Lower Limit Lower level ll Please dispose of used motor oil in a manner that is compatible with the A NOTE environment and local disposal regulations Do not throw it in the trash or pour it on the ground 33 PH3100Ri SM Revision 03 03 2014r1 4 4 Checking the low oil sensor 1 Remove the maintenance cover and locate the oil sensor lead which is between the battery and the side panel Disconnect the low oil sensor while the engine is running Ground the white lead from the indicator module to the engine block to verify that the engine will stop when the low oil alarm lamp is lit 4 After confirming that the engine oil is at the proper level test for continuity between the terminal of the black oil sensor lead and the case of the engine No continuity indicates a normal condition 5 Continuity between the black oil sensor lead and engine when the oil is drained from the engine indicates a normal condition 7 WARNING No continuity after the oil has been drained would indicate a faulty oil sensor or a damaged wire that must be repaired or replaced Failure to do so can lead to permanent damage if the engine runs low on oil White Lead t
32. n chamber 3 Check the valve cone and seat 4 Check for worn piston piston ring or cylinder PH3100Ri SM Revision 03 03 2014r1 3 3 Cylinder compression check 1 Remove the spark plug cap and spark plug 2 Install acompression 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 EA Gauge NP en gt ry C D HOUSE PHBIOORI gt 3 LL BAS NUS dL Remote Switch PH3100Ri SM Revision 03 03 2014r1 3 4 Ignition system Fillthe oil reservoir to the correct level Use F7RTC or equivalent spark plug Spark plug inspection A warning Dont pull the recoil starter or turn the ignition switch to START while touching the high tension wire Turn off the fuel valve Pull the recoil starter several times to release the unburned gas in the cylinder with the engine switch OFF Remove spark plug Install the spark plug into the plug cap Turn the ignition switch to the ON position Attach the negative electrode i e threaded part of the spark plug to your
33. nce replace the spark plug if the resistance is outside of these values Spark plug resistance 3 9K Q SYS rd 4 Measure the plug gap with a wire type feeler gauge Adjust by bending the side electrode if the measurement is not within the specified clearance Spark plug clearance 0 6 0 7mm 0 024 0 028 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 Ibf ft 12 15 Nm 36 PH3100Ri SM Revision 03 03 2014r1 4 7 Valve clearance Caution E Valve clearance inspection and adjustment must be performed with the engine cold Inspection Adjustment 1 Remove spark plug valve cover bolt valve cover and valve cover gasket Spark Plug Valve Cover Gasket Valve Cover T Valve Cover Bolt Vent Hose from Air Fuel Tank Br 3 Vent Hose from Tank Air Cleaner 380cc Carbon BER Canister 37 PH3100Ri SM Revision 03 03 2014r1 Rotate the engine in a clockwise direction until the piston is attop dead center and the intake and exhaust valves are closed 2 Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance 0 10 0 02mm 0 004 0 001 Valve cl en 0 15 0 02mm 0 006 0 001 3 If adjustment is necessary proceed as follows a Secure the rocker
34. nd the left and right side panels Remove the upper frame and the fuel tank as an assembly Remove the inverter and the carburetor assembly Remove the muffler cover muffler exhaust fan exhaust manifold and muffler housing Remove the upper and lower engine covers Remove the valve cover and 4 M10 head bolts DUD mM ES nte Cover 1 X az an l Muffler Case E Q Y Exhaust Manifold RIESE cover D x i 59 PH3100Ri SM Revision 03 03 2014r1 Cylinder Head Alignment Cylinder Head Bolts Sleeves Valve Cover gt l r a Valve Cover Bolt and Rubber Seal 12 2 Cylinder Head Disassembly and Reassembly Valve Guide Exhaust Valve Tappet F n Bon us N J Intake Valve Rocker Arm it Valve spring Rocker arm Retainer Stud Push Rod Lock Nut Rocker Arm Pivot 60 PH3100Ri SM Revision 03 03 2014r1 12 3 Inspection Free length of valve spring Standard 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 Inlet valve 6 465 6 480mm 0 2545 0 2551 6 40mm 0 2520 Exhaust valve 6 455 6 470mm 0 2541 0 2547 6 40mm 0 2520 INVI 61 PH3100Ri SM Revision 03 03 2014r1 13 Crankshaft Piston 13 1 Cranks
35. ness Normal Replace the inverter unit 21 PH3100Ri SM Revision 03 03 2014r1 3 9 Engine speed doesn t increase with economy system ON and a load connected Abnormal Perform the generator Check the AC output troubleshooting following the instruction of No or low AC output Normal Abnormal Check the step motor Replace the step 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 3 10 No or low AC output Is the overload indicator light ON OFF Is the engine speed normal Economy switch ON 2500 100 rpm OFF 3600 100 rpm Disconnect the load and reset the inverter Abnormal Perform the throttle control system test Abnormal Stop the engine and check the AC receptacles Replace the AC receptacle Disconnect the 6P connector between the inverter and stator unit pull the recoil starter with force and measure the AC voltage between the 1 Check and repair stator wire black terminals and white terminal Abnormal harness or replace stator 2 Rotor inner magnetism Black Black Black gt 30V decreased replace the rotor White White gt 1V Normal Abnormal Measure stator output with unit running Replace stator 22 PH3100Ri SM Revision 03 03 2014r1 3 11 Measuring stator output voltage wh
36. ngine or chassis 6 When the ignition switch is turned off there must be 12 VDC on the green black wire for several seconds If there is no 12 VDC replace the BFP controller Green Black Connects to Fuel Shutoff Solenoid Red Black Connects to DC Power Supply from Voltage Regulator Connects to Me Connects to the Ignition the Ignition Switch Coil 29 PH3100Ri SM Revision 03 03 2014r1 3 18 Engine will start and then shut down This condition can affect the ignition switch remote and manual start system What to check for 1 Check engine oil level and fill to the proper level as required 2 Ifthe low oil light comes on and the oil level is correct refer to low oil sensor trouble shooting section Remove the front control panel and unplug the remote receiver 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 E Air Filter Cover Inverter m 30 PH3100Ri SM Revision 03 03 2014r1 4 Maintenance 4 1 Maintenance schedule Regular Service period 1 Perform at every indicated month or operating hour interval whichever occurs first Maintenance i Every3 Every6 Procedure Months Months Or Every Year Or Fuel Filter Check adjust Valve clearance Every 2 years R
37. o the Indicator Module Black Lead to the Low Oil Sensor Check Continuity between the Black Oil sensor Lead and Ground 34 PH3100Ri SM Revision 03 03 2014r1 4 5 Air Cleaner Inspection Cleaning Loosen the panel screws and remove the side maintenance cover Remove the four cartridge retaining screws Remove the filter cartridge and the fine and coarse filter elements Wash the elements in a non flammable or high flash point solvent and dry them thoroughly Soak the fine element in clean engine oil and squeeze out the excess oil aa on Reinstall the coarse and fine air cleaner elements and the air filter cartridge Tighten the four cartridge screws securely 7 Reinstall the maintenance cover and tighten the screws securely Air Cleaner Caution B A dirty air cleaner will restrict air flow to the carburetor reducing engine performance If the engine is operated in dusty areas clean the air cleaner more often than specified in the Maintenance Schedule BI Never run the engine if there is no element or if the filter is damaged as it will cause serious damage to the engine 35 PH3100Ri SM Revision 03 03 2014r1 4 6 Spark plug Inspection Cleaning 1 Remove the spark plug cap and remove the spark plug 2 Remove carbon or other deposits with a plug cleaner or stiff wire brush Check the sealing washer for damage 3 Measure the plug resista
38. ot Backpressure Check Valve Choke Return Spring Choke Lever M Vacuum Pot linkage Hose to j Backpressure Valve 44 PH3100Ri SM Revision 03 03 2014r1 6 7 High Altitude jet installation Remove the carburetor Remove the fuel cut off solenoid Remove the fuel bowl retainer bowl and gasket Remove the main jet and emulsifier tube Carefully inspect all rubber seals and O rings Replace the main jet with a high altitude jet and reassemble carburetor Reinstall and check for fuel leaks DUDEN ee Mrs Rubber bowl Seal iz Emulsifier Tube Main Jet n Fuel Bowl O ring mu Fuel Cut Off Solenoid Fuel Bowl Retainer 45 PH3100Ri SM Revision 03 03 2014r1 7 Control panel 7 1 Disassembly Installation Remove 6 Mounting Screws 12V DC Circuit Breaker 120V 20 amp 30 amp Circuit Breakers 120V 30amp L5 30 Remote and Economy 120V 20amp Duplex 5 20 46 Switches Ignition Switch Indicator Module 4 Module Cover 12V Receptacle Hour Meter Ignition Key Overload and Stop Buttons PH3100Ri SM Revision 03 03 2014r1 8 Outer generator housing 8 1 Disassembly Installation Gas Cap Sight Rubber Grommet T Rubber Grommet Lo Fuel Gauge Handle Screw A Handle Starter Solenoid Right Cover mm Oil Access Cover Fold O
39. s no resistance repair or correct as necessary 4 Replace the coil if there is no resistance or the value is outside of the values shown Primary resistance 1 4 2 00 The blue wire should be connected to the chassis ground 1 Check continuity between the blue and black wires if installed 2 Pin Coil Connector 2 If not installed check continuity between the black wire and coil bracket Check the secondary resistance between the black wire and spark plug cap 5 Tocheck the secondary resistance attach one lead of the tester to the black wire of the primary plug of the ignition coil and the other lead to the spark plug cap 6 Ifthere is no resistance remove the spark plug cap and check the lead itself 7T 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 0kO 52 PH3100Ri SM Revision 03 03 2014r1 9 5 Ignition 0011 Adjustment Replacement 1 Follow step 1 through 8 as outlined in section 8 1 2 Adjust the clearance between the ignition coil and the outer magnet trigger of the rotor 3 Loosen the ignition coil bolts and Insert a feeler gauge between the ignition coil and the permanent magnet of the rotor 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 Ignition coil
40. ssembly S Starter Cup ar e Inlet Fan 9 2 Starter motor 1 Follow steps 1 through 8 as outlined in section 8 1 2 Remove 2 M8 flange bolts 50 PH3100Ri SM Revision 03 03 2014r1 9 3 Start relay 1 Using a volt ohm meter check the resistances of the electromagnetic coil of the starter relay by connecting the red positive lead to the 74 spade and the black negative lead to the metal body of the relay Resistance 5 4 Q 1 10 2 Check the function of the start relay by connecting 12 volts to the Y spade terminal and 12 volts negative to the metal base or body There should be a clicking sound as the relay is activated While the relay remains activated use the volt ohm meter check continuity between the two lugs lf 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 Connect 12volt Negative Checking Resistance Checking Continuity Connect 12volts PH3100Ri SM Revision 03 03 2014r1 9 4 Ignition 0011 Inspection 1 Remove the control panel and locate the 2 pin primary coil plug with a Blue and Black wire and unplug it from the control panel 2 Attach the two leads of the tester to the Blue and Black wires and measure the primary resistance of the ignition coil 3 Ifthere is no resistance check for continuity between the Blue wire and chassis ground If there i
41. tsennonsensntsenonannn 11 2 2 Important Safety precautions em teh te ane b Pp tte et ende ere fere 11 PASSI nM AAN IC E Em 12 2 4 Serial number location ree tite eer nn hr e ede aeta ete ee ttes eher enit 13 2 5 Engine maintenance standards o ird ee rette re t tte eset kid te rae ehe egeo rego e di 13 LOMO ne e eed ente med e tee ed en tit se e tete ee ee RR ens 15 PACA dnd rie irlanda dedicada ehren 15 3 DOUBLE A te tret aeter tete ent pedit none Wed edo dette o D edt etd 15 3 1 General symptoms and possible causes ninni ninina aa o ea ie aS aAa A ea a E SS AEN ies 15 3 2 Hard starting rd mette dr tees Ue pt tette etaient diee eite dones 16 3 5 CyImder compression Checks ai tos t ROO 17 SA IenitiOn System 2 02 eerte eter tei eii dete i e a e sale lee ten olei te ate desee roads es 18 3 5 Engine oil level is low but engine does not stop uunessessessensnesnennussesnennennannnennennonnnnnnennennennnnsnennennonnnenennenannn 20 3 6 Engine stops running Throttle is in the correct position sess eere nennen 20 3 7 Engine speed can t increase or is unstable choke is in the correct position 21 3 8 Engine speed too Mien Or too dlow eed ree neben tr obo ne e peior epe kao eor ote eet ent 21 3 9 Engine speed doesn t increase with economy system ON and a load connected 22 3 10 No or low AC OUEDUL trim a pU DO m rie RE PROP 22 3 11 Measuring stator output voltage while running sese nenn
42. ver y Handle E SH Fuel Knob Left Wheel Control Panel Cove Swivel Wheel New handle Beginning with Serial Maintenance Number 100317377059001 Cover 47 PH3100Ri SM Revision 03 03 2014r1 9 Recoil starter Disassembly Reassembly Caution E Drain all gasoline from the fuel tank before disassembly E Keep the unit away from all heat flame and sparks Disconnect the battery Remove front panel Drain all gasoline from the fuel tank Remove the inverter Remove 3 M6 flange bolts and the recoil starter Reinstall the inverter and end panel el de DU E 48 PH3100Ri SM Revision 03 03 2014r1 9 1 Inlet Fan Cover Caution E Drain all gasoline from the fuel tank before disassembly E Keep the unit away from all heat flame and sparks Disconnect and remove the battery Remove the front and rear end panels and the left and right side panels Remove the upper frame and the gas tank as an assembly Remove the inverter Disconnect all wires from the stator assembly 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 MA NO i n Sae ln ee D pa 49 PH3100Ri SM Revision 03 03 2014r1 8 Remove the carburetor assembly and the inlet fan cover r Starter Motor Rotor and Stator 5 D A
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