POWERHOUSE
®
PH3300i Digital Inverter Generator
SERVICE MANUAL
PREFACE
This manual covers the construction, function and servicing procedure of the POWERHOUSE® PH3300i
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. Keystone Automotive Operations, Inc.
reserves the right to make changes without incurring any obligation whatsoever. No part of this publication
may be reproduced without written permission.
Pay special attention to statements preceded by the following words:




Indicates a strong possibility of severe personal injury or death if instructions are not
followed.
Indicates a possibility of personal injury or equipment damage if instructions are not
followed.
Gives helpful information.
Please read and review the PH3300 Owner’s Manual before using this Service
Manual.
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PH3300i SM, Rev. 2017-01-20
CONTENTS
PREFACE ...........................................................................................................................................................2
CONTENTS ........................................................................................................................................................3
1. GENERAL SPECIFICATIONS .......................................................................................................................6
1.1 Specifications............................................................................................................................................6
1.2 Characteristics ..........................................................................................................................................7
1.3 Wiring Diagram .........................................................................................................................................8
2. SERVICE INFORMATION..............................................................................................................................9
2.1 The Importance of Proper Servicing.........................................................................................................9
2.2 Important Safety Precautions ...................................................................................................................9
2.3 Servicing Rules .......................................................................................................................................10
2.4 Electrical Precautions .............................................................................................................................10
2.5 Engine Serial Number and Bar Code Number ....................................................................................... 11
2.6 Engine Maintenance Specifications ....................................................................................................... 11
2.7 Alternator Electrical Specifications (Stator/Rotor Windings) ..................................................................13
2.8 Torque Values .........................................................................................................................................13
3. MAINTENANCE ...........................................................................................................................................14
3.1 Maintenance Schedule ...........................................................................................................................14
3.2 Battery Maintenance...............................................................................................................................15
3.2.1 12V 10Ah AGM Starting Battery ......................................................................................................15
3.2.2 3.6V Li-ion Ignition Batteries ............................................................................................................15
3.3 Checking the Oil Level............................................................................................................................16
3.4 Changing Oil ...........................................................................................................................................17
3.5 Air Filter Inspection and Cleaning...........................................................................................................18
3.6 Spark Plug Inspection and Cleaning ......................................................................................................19
3.7 Valve Clearance Inspection and Adjustment ..........................................................................................20
3.8 Evaporation Control System ...................................................................................................................21
3.9 Replacing Fuel Filter...............................................................................................................................22
3.10 Spark Arrestor .......................................................................................................................................23
4. TROUBLESHOOTING .................................................................................................................................24
4.1 Starter Does Not Crank ..........................................................................................................................25
4.2 Hard Starting...........................................................................................................................................26
4.2.1 Pre-Start Throttle Location ...............................................................................................................27
4.3 Cylinder Compression Check .................................................................................................................28
4.4 Ignition System .......................................................................................................................................29
4.4.1 Checking for Spark ..........................................................................................................................30
4.4.2 Ignition Coil/Trigger Assembly Inspection........................................................................................31
4.4.3 Ignition Switch Inspection ................................................................................................................32
4.5 Oil Level Sensor Fails to Stop Engine with Low Oil ...............................................................................33
4.5.1 Checking the Low Oil Sensor ..........................................................................................................34
4.6 Engine Stops Running ............................................................................................................................35
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PH3300i SM, Rev. 2017-01-20
4.6.1 Fuel Pump Testing ...........................................................................................................................36
4.7 Engine Speed Cannot Increase or is Hunting ........................................................................................37
4.8 Engine Speed Too High ..........................................................................................................................37
4.9 No or Low AC Output..............................................................................................................................38
4.10 Measuring Stator Main Output Voltage While Running .......................................................................39
4.11 No DC Output At Battery Charge Receptacle ......................................................................................40
4.12 Starting Battery Will Not Charge ..........................................................................................................40
4.13 Voltage Regulator Testing.....................................................................................................................41
4.14 Engine Runs-on or Backfires After Being Turned Off...........................................................................42
4.15 Engine Will Start Then Shut Down .......................................................................................................42
5. REPAIR ........................................................................................................................................................43
5.1 Carburetor...............................................................................................................................................43
5.1.1 Removal / Installation of Carburetor ................................................................................................43
5.1.2 Throttle Control – Step Motor ..........................................................................................................44
5.1.3 Backfire Prevention Solenoid (BFP) ................................................................................................46
5.1.4 Manual Choke Assembly .................................................................................................................47
5.1.5 High Altitude Jet ...............................................................................................................................48
5.2 Control Panel ..........................................................................................................................................49
5.2.1 Disassembly / Installation ................................................................................................................49
5.3 Outer Generator Housing .......................................................................................................................50
5.3.1 Disassembly / Installation ................................................................................................................50
5.4 Recoil Starter ..........................................................................................................................................51
5.4.1 Disassembly / Reassembly..............................................................................................................51
5.5 Starter motor ...........................................................................................................................................52
5.5.1 Starter Testing ..................................................................................................................................52
5.5.2 Starter Removal / Replacement.......................................................................................................53
5.6 Starter Relay ...........................................................................................................................................54
5.6.1 Testing Starter Relay on Generator .................................................................................................54
5.6.2 Bench Testing the Starter Relay ......................................................................................................55
5.7 Intake Fan Cover ....................................................................................................................................56
5.8 Ignition Coil/Trigger Assembly Adjustment / Replacement ....................................................................58
5.9 Stator and Rotor .....................................................................................................................................59
5.9.1 Stator Inspection ..............................................................................................................................59
5.9.2 Stator Removal and Reassembly ....................................................................................................60
5.10 Inverter Inspection / Adjustment / Replacement ..................................................................................61
5.10.1 Inverter Removal / Preparation for Adjustment..............................................................................61
5.10.2 Inverter Adjustment / Replacement ...............................................................................................62
5.10.3 Inverter Ignition Power ...................................................................................................................63
5.11 Muffler Removal / Replacement ...........................................................................................................64
5.12 Engine Exploded View..........................................................................................................................65
5.13 Cylinder Head / Valves .........................................................................................................................68
5.13.1 Cylinder Head Removal .................................................................................................................68
5.13.2 Cylinder Head Disassembly and Reassembly ..............................................................................69
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PH3300i SM, Rev. 2017-01-20
5.13.3 Valve and Spring Inspection ..........................................................................................................70
5.14 Crankshaft / Camshaft / Piston.............................................................................................................71
5.14.1 Disassembly and Reassembly.......................................................................................................71
5.14.2 Alignment of Timing Marks.............................................................................................................72
5.14.3 Camshaft Inspection ......................................................................................................................73
5.14.4 Piston / Connecting Rod ................................................................................................................74
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PH3300i SM, Rev. 2017-01-20
1. GENERAL SPECIFICATIONS
1.1 Specifications
Dimensions And Weights
Model
PH3300i
Overall Length
603mm (23.75”)
Overall Width
476mm (18.75”)
Overall Height
546mm (21.25”)
Net Weight
61 kg (134 lbs.)
Engine
Model
XG-177F
Type
4-stroke,OHV, single cylinder, Gasoline engine
Displacement
270cc
Bore x stroke
77 × 58
Maximum horsepower
6.8
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
Lube oil
SAE 10W-30 (SF/SG grade ) above 0°C (32°F);
SAE 0W-30/0W-40 below 0°C (32°F)
Oil capacity
1.0 L (35 oz.)
Starting system
Electric & Recoil
Stopping system
Primary circuit ground
Fuel used
Automotive unleaded gasoline
Alternator type
Multi pole rotation type
Alternator structure
Self-ventilation drip-proof type
Excitation
Self-excitation (Magnet type)
Phase
Single phase
Rotating direction
Clockwise (Viewed from the generator)
Frequency regulation
AC-DC-AC conversion (Inverter type)
Alternator
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PH3300i SM, Rev. 2017-01-20
1.2 Characteristics
Model
PH3300
Maximum output AC
3300W
Rated output AC
3200W
Rated frequency
60HZ
Rated voltage AC
120V
Rated voltage DC
12V
Rated current AC
26.7A
Rated current DC
8.3A
Power factor
1.0cosφ
Voltage variation rate
Momentary
10%max.
Average
1.5%max.
Average time
Voltage stability
3 sec. max.
±1%
Frequency variation rate Momentary
1%max.
Average
1%max.
Average time
Frequency stability
1 sec. max.
±0.1%
Insulation resistance
10MΩmin.
AC circuit protector
20A and 30A (120V)
DC circuit protector
10A
Fuel tank capacity
16.3L (4.3 gal)
Continuous running time
10.9 hours / 16.6 hours
(at rated load ½ at ¼ load)
Noise level
(Zero load to full load)
7
63-78 dB @ 7m (23’)
PH3300i SM, Rev. 2017-01-20
1.3 Wiring Diagram
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PH3300i SM, Rev. 2017-01-20
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 and injury to the operator.

Improper servicing can cause an unsafe condition that can lead to serious injury
or death.


Follow the procedures and precautions in this service manual carefully.

Failure to follow maintenance instructions and precautions can cause you to be
seriously injured or killed. Follow the procedures and precautions in this service
manual carefully.
Some of the most important precautions are given below. However, we cannot
warn of every conceivable hazard that can arise in performing servicing or repairs.
Only you can decide whether you should perform a given task.
2.2 Important Safety Precautions
Be sure you have a clear understanding of all basic shop safety practices. Wear appropriate clothing
and personal protective equipment. When performing servicing or repairs, the below CAUTION steps
must be followed:

Read the instructions before you begin any servicing, be sure you have the
equipment and skills required to perform the tasks safely.
■
Be sure that the engine is off before you begin any servicing or repairs.

To avoid carbon monoxide poisoning from engine exhaust, make sure there is
adequate ventilation whenever you run the engine.

To avoid burns from hot engine parts and hot exhaust, let the engine and exhaust
cool before touching them.
■
To avoid injury, use caution when working around 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 cautious when working around
gasoline. Use only a nonflammable solvent and not gasoline to clean parts. Keep
all cigarettes, sparks and flames away from fuel and all fuel-related parts.
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PH3300i SM, Rev. 2017-01-20
2.3 Servicing 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.
4. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before
reassembly.
5. After reassembly, check all parts for proper installation and operation.
6. 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.
7. 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.
2.4 Electrical 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.
2. Check the connector terminals for bent pins, excessive stretching, missing terminals or other
abnormalities before connecting the connector.
3. To connect, insert the connector completely into the receptacle. If the connector is a locking type,
be sure that it is locked securely.
4. 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 a fine emery paper or equivalent material
before connecting the connector.
5. Secure the harness clips in the specified locations on the frame and clamp the wire harnesses.
6. Clamp the wire harnesses securely so that they do not interfere with rotating parts, moving parts
or hot parts.
7. Route and connect the wire harnesses as shown in the Service Manual. Be sure that the
harnesses are not loose, twisted or pulled tight.
8. Route the wire harnesses properly so that they do not come in contact with sharp edges or
corners or the ends of any bolts or screws.
9. If a wire harness contacts the ends of any bolts or screws or sharp edges or corners, protect that
part of the harness by wrapping insulating tape on the sharp surface. If the wire harness has a
grommet, install the grommet securely.
10. Take care not to pinch the wire harnesses during installation of a part. If a wire harness has
damaged insulation, repair by winding with the electrician’s insulating tape.
11. Before using test equipment, carefully read the manufacturer’s instructions and follow the
instructions in this Service Manual. Be sure that the test equipment battery is fully charged and
verify that the unit is operating correctly before you begin testing.
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PH3300i SM, Rev. 2017-01-20
2.5 Engine Serial Number and Bar Code Number
The generator bar code number (BCN) and the engine serial number (ESN) identify your particular
unit and are necessary when ordering parts and accessories. These two numbers are used by your
dealer and Keystone Automotive Operations for warranty administration and must be supplied before
any work can be done.
The BCN is found in three locations:
1. On the side of the generator, lower left of the oil access door.
2. On the back of the Owner’s Manual.
3. On the outside of the shipping carton.
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 (Fig. 1).
Fig. 1
2.6 Engine Maintenance Specifications
Part
Engine
Item
Specification
Maximum speed without load
Cylinder
Sleeve I.D.
Skirt O.D.
Piston
Pin bore I.D.
Piston pin
O.D.
Height
Ring side clearance
Piston ring
1st ring
Ring end clearance
Width
11
3600±100rpm
77.000-77.020mm
(3.0315”-3.0323”)
76.960-76.980mm
(3.0299”-3.0307”)
18.002-18.008mm
(0.7087”-0.07090”)
17.994-17.000mm
(0.7084”-0.7087”)
1.97-1.99mm
(0.0776”-0.0783”)
0.02-0.06mm
(0.001”-0.002”)
0.15-0.25mm
(0.006”-0.010”)
3.4-3.6mm
(0.134”-0.142”)
Service limit
—
77.105mm
(3.0356”)
76.85mm
(3.0256”)
18.05mm
(0.7106”)
17.95mm
(0.7067”)
1.87mm
(0.0736”)
0.15mm
(0.006”)
1.0mm
(0.040”)
3.2mm
(0.126”)
PH3300i SM, Rev. 2017-01-20
2.5 Engine Maintenance Specifications (continued)
Part
Item
Specification
Height
Ring side clearance
2nd ring
Ring end clearance
Width
Piston ring
(continued)
Height
Ring side clearance
Oil ring
Ring end clearance
Width
Small end I.D.
Connecting
rod
Big end I.D.
Crankshaft
Crank pin O.D.
IN
Valve
clearance
Valves
EX
IN
Stem O.D.
EX
Valve spring
Guide I.D.
IN/EX
Seat width
Free length
IN/EX
IN/EX
Cam Lobe
Cam Lobe height
Carburetor
Main jet
Float height
Pilot screw opening (Fixed)
Spark plug
Gap
Ignition coil
Resistance
Trigger coil
Resistance
Primary side
Second side
12
1.97-1.99mm
(0.0776”-0.0783”)
0.02-0.06mm
(0.001”-0.002”)
0.15-0.25mm
(0.006”-0.010”)
3.40-3.60mm
(0.134”-0.142”)
3.40-3.60mm
(0.134”-0.142”)
0.03-0.18mm
(0.001”-0.007”)
0.20-0.50mm
(0.008”-0.020”)
2.3-2.7mm
(0.090”-0.110”)
18.006-18.017mm
(0.7089”-0.7093”)
33.020-33.033mm
(1.3000”-1.3005”)
32.967-32.980mm
(1.2979”-1.2984”)
0.10±0.02mm
(0.004” ±.001”)
0.15±0.02mm
(0.006” ±.001”)
6.46-6.48mm
(0.254”-0.255”)
6.455-6.470mm
(0.2541”-0.2547”)
6.500-6.530mm
(0.2559”-0.2571”)
0.8mm (0.03”)
39.1mm (1.54”)
31.700-31.780mm
(1.2480”-1.2512”)
0.79mm (.0310”)
12
N/A
0.6-0.7mm
(0.024”-0.028”)
1.4-2.0 Ω
11.0-15.0kΩ
113-122 Ω
Service limit
1.87mm
(0.0736”)
0.15mm
(0.006”)
1.0mm
(0.040”)
3.20mm
(0.126”)
3.20mm
(0.126”)
0.24mm
(0.009”)
1.0mm
(0.040”)
2.2mm
(0.087”)
18.08mm
(0.712”)
33.09mm
(1.303”)
32.90mm
(1.295”)
----6.40mm
(0.2520”)
6.40mm
(0.2520”)
6.56mm
(0.2583”)
1.8mm (0.07”)
37.5mm (1.48”)
31.00mm
(1.2205”)
—
—
—
—
—
—
—
PH3300i SM, Rev. 2017-01-20
2.7 Alternator Electrical Specifications (Stator/Rotor Windings)
Part
Item
Wire color
Specification(Ω)
DC winding
Sub winding
Main winding
Resistance
Resistance
Resistance
blue-blue
white-white
black-black-black
0.02-0.06
0.10-0.16
0.25-0.35
2.8 Torque Values
M8x40
M12x1x13
M8x35
M16x1.5
M5 Bolt, nut
M6 Bolt, nut
ft-lb
21-24
9-11
21-23
66-74
4-6
6-7
Tightening torque
N∙m
28-32
12-15
28-31
90-100
6-8
8-10
M8 Bolt, nut
15-17
18-22
M10 Bolt, nut
41-44
55-60
Item
Specification
Connection rod bolt
Spark plug
Crankcase cover
Flywheel nut
Standard torque
■
Use standard torque values for fasteners that are not listed in this table.
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PH3300i SM, Rev. 2017-01-20
3. MAINTENANCE
3.1 Maintenance Schedule
Regular Service period. Perform at every indicated month
Item
or operating hour interval, whichever occurs first.
Maintenance
Procedure
1st Month
Every 3
Every 6
or 4 to 6
Months or
Months or
Hours
50 HRS
100 HRS
1x per Year
Each Use
or 300 HRS
O
Check
Engine Oil
O
Change
O
O
Check
Air cleaner
O(2)
Clean
Spark Plug
Spark Arrester
Clean - adjust
O
Clean
O
O
Check
Fuel Filter
Replace
O(2)
Check - Adjust
O(3)
Fuel tank & strainer
Clean
O(2)
Fuel line
Check
Valve clearance
Every 2-years (Replace as necessary)
Charge monthly during long term storage.
12V 10Ah AGM
Clean - Charge
Check terminals for corrosion monthly, clean as needed.
Starting Battery
Expected battery life is 2 years, but can be affected by operating environment.
Check the voltage and inspect the terminals monthly during long term storage.
The voltage should be 3.2-4.0V depending on the temperature. If the voltage
3.6V Li-ion
Inspect - Replace
Ignition Batteries
is low, or the terminals are corroded, replace the Li-ion batteries.
Expected battery life is 2 years, but can be affected by operating environment.
Notes:
(1) Log Hours of operation to determine proper maintenance
(2) Service more frequently when used in dusty areas.
(3) These items should be serviced by an authorized dealer unless the owner has the proper tools
and is mechanically proficient.
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PH3300i SM, Rev. 2017-01-20
3.2 Battery Maintenance
It is recommended that the starting battery and ignition batteries be fully charged before starting any
diagnostic work on the generator.
3.2.1 12V 10Ah AGM Starting Battery
This generator comes equipped with 12V, 10Ah, AGM starting battery located behind the
maintenance door. This battery is charged by the generator during periods of frequent usage; if
the battery is not holding a charge refer to (section 4.12). During periods of infrequent use it is
recommended that the battery be charged monthly. A TC2-P plug-in trickle battery charger or
equivalent is recommended. The battery will be damaged by improper charging or overcharging.
If this battery appears swollen or damaged, replace it. Do not replace this battery with one that
has less than 10Ah capacity. It is recommended that the battery be replaced with the exact OEM
replacement battery.
3.2.2 3.6V Li-ion Ignition Batteries
This generator comes equipped with two Panasonic NCR18650B 3.6V Li-ion ignition batteries
which have a 3350mAh capacity and protective circuitry (Fig. 2). They are located in a tray,
mounted on the air cleaner cover. They can be accessed by removing the control panel and
carefully letting it hang from its connections (Fig. 3). These batteries provide power for pre-start
throttle location, and auxiliary ignition power. They are charged while the generator is running.
Inspect them periodically, or as part of a troubleshooting procedure.
Remove the batteries from their tray for inspection; their voltage should be 3.2-4.0V depending
on the temperature. If the voltage is ≤2.7V, replace both of the Li-ion batteries. If the Li-ion
batteries are not maintaining their charge during frequent generator usage, then check the
charging voltage between the red and black wires of the Li-ion battery connector (Fig. 3) while
the generator is running. The charging voltage can be checked with the batteries in, or out, of the
tray. It should be 3.7-4.2V. If the voltage is within this range but the batteries are not maintaining
their charge, replace the batteries. If the charging voltage is not in this range then test the voltage
regulator refer to (section 4.13).
Check the Li-ion batteries’ voltage and inspect the terminals monthly during long term storage. If
the voltage ≤2.7V or the terminals are corroded, replace the Li-ion batteries. This battery must be
replaced with the OEM replacement battery or the exact equivalent (this battery is typically listed
as 3.7V and 3400mAh by most retailers).
Fig. 2
Fig. 3
Put the positive end of both
of the Li-ion batteries
towards the top of the tray.
Li-ion Battery
Connector
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PH3300i SM, Rev. 2017-01-20
3.3 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. If the oil level is low, add oil until it reaches the edge of the upper line on the dipstick (when
screwed in as shown in Fig. 4).
4. Re-install the dipstick and the engine oil access door before restarting your generator.
Fig. 4
Upper Limit
Lower Limit
Upper level
Lower level
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PH3300i SM, Rev. 2017-01-20
3.4 Changing Oil
■
Make sure to turn the engine switch and fuel lever OFF before draining.
■
Drain the oil while the engine is still warm to assure rapid and complete draining.
1. Loosen the screw on the engine oil access cover and remove the cover.
2. Remove the oil filler cap.
3. Install the oil drain pipe.
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 cover and tighten the screw securely.
Engine oil capacity: 1.0L (35 oz.)
Fig. 5
Upper Limit
Lower Limit
■
Upper level
Lower level
Please dispose of used motor oil in a manner that is compatible with the
environment and local disposal regulations. Do not throw oil in the trash or pour oil
on the ground.
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PH3300i SM, Rev. 2017-01-20
3.5 Air Filter Inspection and Cleaning
1. Loosen the panel screws and remove the side maintenance door.
2. Remove the two filter cartridge retaining screws.
3. Remove the filter cartridge and the filter element.
4. If filter element and the filter case are soaked with excessive engine oil this could be a sign of
excessive blow-by or a defective PCV valve. Pull the spark plug to check for signs of oil burning
or fouling (section 3.6). If the plug looks normal but the PCV hose is full of oil, replace the PCV
valve (must replace the whole valve cover).
5. Wash the filter element in a non-flammable or high flash point solvent and dry them thoroughly.
6. Soak the filter element in clean engine oil and squeeze out any excess oil.
7. Reinstall the filter element and the air filter cartridge. Tighten the two cartridge screws securely.
8. Reinstall the maintenance door and tighten the screws securely.
Fig. 6
Air Filter Cartridge
Air Filter Element
Maintenance Door
Air Filter Case
■
A dirty air filter will restrict air flow to the engine, reducing engine performance. If
the engine is operated in dusty areas, clean the air filter more often than specified
in the Maintenance Schedule (section 3.1).
■
Never run the engine if there is no filter element or if the filter is damaged, as it will
cause serious damage to the engine.
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PH3300i SM, Rev. 2017-01-20
3.6 Spark Plug Inspection and Cleaning
Fig. 7
1. Remove the spark plug using a plug wrench
and carefully inspect it. Compare the color and
deposits on the plug to Fig. 7. It should look
normal, or worn if it is time for replacement.
Evidence of lean, rich or flooded conditions
indicate there is a carburetor, choke, or fuel
delivery issue. Ash deposits are evidence of oil
burning under normal combustion conditions
and usually show up toward the end of the
engine’s service life; more frequent plug
replacement will be required. Oil fouling is
evidence of far too much oil entering the
cylinder, usually engine repair will be required
to fix the problem (sections 5.12, 5.13 & 5.14).
Oil burning can also be caused by a faulty
PCV valve (built into the valve cover). This will
cause large amounts of engine oil to get pulled
through the PCV hose, collect in the air
cleaner, and get sucked into the carburetor. If
this is the case, try replacing the PCV valve
(valve cover).
NEW
LEAN
NORMAL
FLOODED
Carbon– Too Rich
WORN
Ash deposits Burning oil
Oil Fouled
2. Remove carbon or other deposits with a plug cleaner or stiff wire brush. Check the sealing
washer for damage.
Spark Plug Type
3. Measure the plug
Spark Plug Resistance
F7RTC
3 - 9 kΩ
resistance; replace the spark
plug if the resistance is
outside of these values.
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 tolerance.
0.6 – 0.7mm
Spark Plug Gap
0.6 - 0.7mm (0.024” - 0.028”)
5. Install the plug finger tight to seat the washer and then tighten with a plug wrench. Torque the
spark plug to 11-13Nm (8-10ft-lbs) or ⅛ of a turn after seating with a previously compressed
washer, or ¼ turn after seating with a new uncompressed washer.
Torque valve is 8.0-10 ft.-lbs. (11-13 Nm)
19
PH3300i SM, Rev. 2017-01-20
3.7 Valve Clearance Inspection and Adjustment
■
Valve clearance inspection and adjustment must be performed with the engine
cold.
1. Remove spark plug, valve cover bolt, valve cover and valve cover gasket.
Spark Plug
Fig. 8
Valve Cover Gasket
Valve Cover
Valve Cover
Bolt
2. Rotate the engine in a clockwise direction until the piston is at top dead center (TDC) and the
intake and exhaust valves are closed.
3. Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance,
see Fig. 9.
Valve clearance
0.10 ± 0.02mm (0.004” ±0.001”)
0.15 ± 0.02mm (0.006” ±0.001”)
Intake
Exhaust
4. If adjustment is necessary, proceed as follows:
a. Secure the rocker arm adjustment nut and loosen the jam nut.
b. Adjust the rocker arm nut until the desired valve clearance is attained.
c. Secure the rocker arm nut and tighten the jam nut. Recheck the clearance.
5. Clean the cylinder block and valve cover.
6. Replace the rubber valve cover seal.
7. Install the removed parts in the reverse order of removal.
Fig. 9
20
PH3300i SM, Rev. 2017-01-20
3.8 Evaporation Control System
The evaporative control system is shown below (Fig. 10). The 380cc carbon canister must be
present and connected as shown to meet CARB evaporative emission standards. Use the OEM
replacement hose, if possible. This grade of hose is commonly available at auto part stores as “fuel
hose”, if the OEM replacement hose is unavailable.
Fig. 10
Fuel Tank
Vent Hose
from Air Filter
Vent Hose
from Tank
Air Filter case
380cc Carbon
Canister
21
PH3300i SM, Rev. 2017-01-20
3.9 Replacing Fuel Filter
■
Use only the OEM Powerhouse replacement fuel filter when servicing this
generator.
■
Take care not to introduce any debris or contaminants in the fuel system during
this process. Contaminants introduced here will likely end up in the carburetor.
1. Remove the 6 control panel screws and carefully allow the control panel to hang out of the way.
2. Remove hose clamps and remove fuel filter (Fig. 11 and Fig. 12).
3. Reassemble in reverse order.
Fig. 12
Fig. 11
22
PH3300i SM, Rev. 2017-01-20
3.10 Spark Arrestor
■
If the generator has been running, the muffler will be very hot. Allow the muffler to
cool before proceeding.
■
The spark arrester must be serviced every 100 hours to maintain efficiency. A
clogged spark arrestor will partially plug the exhaust system causing a substantial
loss in power and performance.
1. Remove the exhaust grill to access the spark arrestor (Fig. 13).
2. Remove the clamp holding the spark arrester to the muffler.
3. Remove the spark arrester.
4. Clean the spark arrestor with a wire or nylon brush and compressed air.
5. Replace the spark arrestor if the wire mesh is perforated or torn.
6. Reinstall the spark arrester.
7. Reinstall the clamp holding the spark arrester to the muffler.
8. Reinstall the exhaust grill.
Fig. 13
Spark Arrestor
Clamp
23
Exhaust Grill
PH3300i SM, Rev. 2017-01-20
4. TROUBLESHOOTING
Trouble Shooting Section Legend
4.1
Starter Does Not Crank
4.2
Hard Starting
4.3
Cylinder Compression Check
4.4
Ignition System
4.5
Oil Level Sensor Fails to Stop Engine with Low Oil
4.6
Engine Stops Running
4.7
Engine Speed Can’t Increase or is Hunting
4.8
Engine Speed Too High
4.9
No or Low AC Output
4.10 Measuring Stator Main Output Voltage While Running
4.11 No DC Output at Battery Charge Receptacle
4.12 Starting Battery Will Not Charge
4.13 Voltage Regulator Testing
4.14 Engine Runs-on or Backfires After Being Turned Off
4.15 Engine Will Start Then Shuts Down
24
PH3300i SM, Rev. 2017-01-20
4.1 Starter Does Not Crank
Make sure the starting battery is in good
condition and fully charged (section
3.2.1). Inspect the battery terminal
connections.
Normal
Check the ignition switch (section 4.4.3).
Abnormal
Abnormal
Charge the battery using recommended
charger. Do a load test to make sure the
battery maintains adequate voltage under
load. Clean battery terminals. Replace
the battery if necessary.
Replace ignition switch and/or repair
wiring faults found.
Normal
Check the ground between the battery
negative terminal and the starter relay
body, the engine block, and control panel.
Abnormal
Repair ground. Clean wire ends and
battery terminals. Remove paint, dirt, oil &
grease, or corrosion from chassis
grounds.
Normal
Check the starter relay (section 5.6).
Normal
Inspect the starter motor wire and
connection. Test the starter motor
(section 5.5).
Abnormal
Abnormal
25
Replace the starter relay (section 5.6).
If starter fails to operate properly replace
the starter motor (section 5.5).
PH3300i SM, Rev. 2017-01-20
4.2 Hard Starting
Make sure the starting and Li-ion
batteries are in good condition and fully
charged (section 3.2). Inspect the battery
terminal connections.
Abnormal
Charge the starting battery using a
recommended charger. Do a load test to
make sure the starting battery maintains
adequate voltage under load. Clean
battery terminals (section 3.2). Replace
any batteries if necessary.
Normal
Check the fuel level in fuel tank.
Sufficient fuel
Loosen the carburetor drain screw to
verify if fuel has reached the carburetor
(section 5.3.1, Fig. 30).
Low fuel
No fuel
Fuel present
Verify manual choke is in the correct
position and operating properly.
Choke needs
adjustment
Choke OK
Check the oil level. The low oil sensor can
cause hard starting if the oil is at, or near,
the critically low level.
Oil level good
Remove and inspect the spark plug for a
worn, wet or fouled electrode (section
3.6).
Good spark plug
Check for spark (section 4.4.1).
Normal
Perform compression test (section 4.3).
Low oil
Worn or
fouled plug
No spark or
weak spark
Low cylinder
compression
Normal
compression
Install the spark plug securely. Engine
should now start and run.
26
Add fuel and start the engine. If starting
with a dry fuel system, use ≥1.5 gallons.
Check the fuel filter (section 3.9), fuel
pump (section 4.6.1), fuel valve, fuel lines
and carburetor for blockage, water in fuel,
and/or a stuck float. Clean or repair as
necessary.
Use FULL choke for cold engine and
during cold weather, use ½ choke for cold
engine and air temp ≥50°F, use no choke
on a hot engine. Verify proper choke
operation (section 5.1.4).
Add oil (section 3.3) and start the engine.
Clean or replace spark plug and perform
any service recommended in (section 3.6)
based on plug deposits.
Refer to ignition troubleshooting (section
4.4). Perform tests and repairs.
1. Check the valve clearance (section 3.7).
2. Check head gasket.
3. Check for carbon deposits on the valves &
combustion chamber. Clean as necessary.
4. Check the valve cone and seat (section
5.13.3). Lap valves, or replace & regrind as
necessary.
5. Check for worn piston, piston ring or
cylinder (section 5.14.4). Re-ring or
overhaul as necessary.
PH3300i SM, Rev. 2017-01-20
4.2.1 Pre-Start Throttle Location
During normal generator shutdown, the inverter sees the 120V output voltage fall to 0V as the
engine dies after the ignition key is turned off. The inverter’s programmed response is to open
the carburetor throttle to demand more power from the engine in an effort to maintain 120V
output. This could leave the throttle wide open after shutdown, and this is not the optimal position
for starting the engine later; especially in cold weather.
Therefore, this generator has a pre-start throttle location sequence programmed into the inverter
to locate the throttle and position it in an optimal position. This occurs immediately after the
ignition key is turned to the ON position but before the starter cranks or the recoil starter is pulled.
It does this by first closing the throttle all the way (to a known position), and then opening it
approximately 20%. This operation only takes a fraction of a second. It does it when the key is
first turned to the ON position, and again between every subsequent starting attempt (if the
engine does not start). This feature is powered by the Li-ion ignition batteries.
If this feature is not working it can make the generator more difficult to start. A procedure for
checking this function is shown below. Note that once the ignition has been turned to the ON
position and throttle has been located, the inverter will remember it is in the correct position for
one minute. Turning the ignition OFF and ON again during this period will not induce another
throttle location process. If the ignition has been turned ON prior to beginning this test, wait at
least one minute before conducting the test below.
1. Remove the maintenance door.
Fig. 14
2. Look in the area circled in red in (Fig. 14) to acquire a
clear view of the throttle plate/step motor linkage. Use a
flashlight if necessary.
3. Turn the ignition key to the ON position while
maintaining a view on the throttle plate/step motor
linkage. It should go through the pre-start throttle
location process immediately when the key is turned
ON. Maintain a careful watch on this area while turning
the key, the process takes only a fraction of a second
and is easy to miss if one looks away while turning the
key. If the motion of the throttle location is witnessed
then the test is over.
4. If there was no pre-start throttle location, Check the condition of the Li-ion batteries (section
3.2.2). If the batteries are faulty, replace them and repeat the test.
5. If the Li-ion batteries are OK, but the throttle failed to
locate, then follow steps 1-7 of (section 5.1.1) to gain
access to the inverter. Check the voltage of the red
wire indicated in (Fig. 15), (do not confuse it with the
red/white wire in the same connector). Pull the
connector out of the inverter and put the positive test
lead of the volt meter on the red wire, and the
negative test lead on the black wire of the Li-ion
battery connector (section 3.2.2, Fig.3). The voltage
should match the LI-ion (battery voltage), 3.2-4.0V. If
there is no, or low voltage, inspect the wiring harness
for breaks or shorts. Repair them and repeat the test.
Be sure to plug the connector back into the inverter
after checking the voltage, and before checking the
throttle location.
Pull the two wire connector
out of the inverter and check
the voltage of the red wire.
Fig. 15
6. If the voltage of the red wire matches the Li-ion
(battery voltage), and the throttle still fails to go
through the pre-start throttle location process, replace the inverter.
27
PH3300i SM, Rev. 2017-01-20
4.3 Cylinder Compression Check
■
Do not crank engine while touching the high tension wire (spark plug wire) as a
severe shock could result.
1. Remove the maintenance door.
2. Remove the spark plug cap.
3. Remove the spark plug (use spark plug wrench from the supplied tool kit).
4. Install a compression gauge in the spark plug hole (Fig. 16).
5. Turn the ignition switch to the START position and hold until the compression gauge no longer
rises. Read compression.
Cylinder compression
Fig. 16
0.45Mpa (65 psi) /800rpm
Pressure
Gauge
28
PH3300i SM, Rev. 2017-01-20
4.4 Ignition System
This section deals with troubleshooting a faulty ignition system. This generator is equipped with
Li-ion batteries that control the step motor during startup and provide auxiliary ignition power. The
main battery requires a minimum of 10.5VDC and the lithium ion batteries require 3.2-4.0V to power
the step motor properly. Before diagnosing an ignition problem, make sure the batteries are fully
charged and the terminal connections are clean and tight (section 3.2). The generator uses a
Capacitive Discharge Ignition. In a (CDI) system, a charging circuit charges a high voltage capacitor
and at the instant of ignition the system stops charging the capacitor, allowing the capacitor to
discharge its output to the ignition coil which sends the voltage to the spark plug.
Check for spark (section 4.4.1). Clean,
inspect and gap the plug (section 4.6).
Plug gap: 0.6-0.7mm (0.024”-0.028”).
No spark
Perform the spark test again using a new
spark plug.
Good
spark
Replace the faulty spark plug.
No spark
Check the 20A in-line fuse located on the
battery power wire.
Fuse good, no spark
Test the ignition switch (section 4.4.3).
No spark
Blown fuse
Abnormal
Good
spark
Disconnect the oil level sensor and
perform spark test.
Replace fuse. Check spark.
Replace switch or repair as required.
Test the oil level sensor (section 4.5.1).
Replace or repair as required.
No spark
Check the ignition coil/trigger assembly
and spark plug wire and cap resistance
(section 4.4.2).
Abnormal
No spark
Abnormal
Check the trigger air gap (section 5.8).
Normal,
Still no spark
Abnormal
Test the ignition power from the inverter
(section 5.10.3).
Replace ignition coil or repair as required
(section 5.8).
Re-adjust the trigger air gap (section 5.8).
Re-test spark. If spark not restored,
replace trigger, reset gap, and re-test
spark.
Replace inverter (section 5.10.1).
Normal,
Still no spark
Check the harness wires to the ignition
coil, trigger and ignition switch for breaks,
shorts or bad connections.
29
Abnormal
Repair or replace wire harness as
necessary.
PH3300i SM, Rev. 2017-01-20
4.4.1 Checking for Spark
■
Don’t pull the recoil starter or turn the ignition switch to START while touching
the high tension wire (spark plug wire).
1. Fill the oil reservoir to the correct operational level.
2. Pull off the spark plug cap and remove the spark plug using a spark plug wrench.
3. Inspect the spark plug color and deposits (section 3.6). Clean or replace plug, as necessary
before checking spark. Make sure you are using an F7RTC or equivalent spark plug.
4. Install the spark plug into the plug cap.
5. Attach a ground wire between the engine block and the negative (-) electrode (the steel body
of the spark plug) (Fig.17).
6. Crank the engine over using the ignition key and watch the spark plug gap for signs of spark.
A healthy ignition system will produce a spark as shown in (Fig. 18).
7. If there is no spark, or a weak spark; continue following the ignition troubleshooting flowchart.
Ground Wire
Fig. 17
Fig. 18
30
PH3300i SM, Rev. 2017-01-20
4.4.2 Ignition Coil/Trigger Assembly Inspection
The ignition coil/trigger assembly (Fig. 20) is mounted on the engine block, above the rotor,
under the inlet fan cover. It can be tested without removal from the unit using the procedure
below. When bench testing the assembly, use the ground wire indicated in (Fig. 20) instead of
chassis ground. See (section 5.8) for replacement of the ignition coil/trigger assembly.
Primary resistance
0.4-1.0Ω
Secondary resistance
7.5-8.1kΩ
Trigger resistance
113-122Ω
1. Remove the control panel screws and carefully let it hang from its connections. Locate the
6-pin ignition coil/trigger connector, and unplug it from the wiring harness (Fig. 19).
2. Attach the two leads of the tester to the red wire and black wire and measure the primary
resistance of the ignition coil. The primary coil resistance should be between 0.4-1.0Ω.
3. Check the red and black wire separately for continuity to chassis ground and the spark plug
cap.
4. If the primary coil resistance is outside the specified range, or there is any continuity found in
step 3, replace the ignition coil/trigger assembly.
5. To check the secondary resistance, attach one lead of the tester to chassis ground (or the
ground wire of the ignition coil) and the other lead to the spark plug cap. The secondary coil
resistance should be between 7.5-8.1kΩ.
6. If the resistance is too high, remove the spark plug cap and check it again through the spark
plug wire itself. If the resistance is within range through the spark plug wire, but not the wire
and cap; replace the spark plug cap.
7. Replace the ignition coil/trigger assembly if the secondary resistance is outside of the
specified range.
8. Attach the two leads of the tester to the green/white wire and blue/white wire of the 6-pin
connector to measure the resistance of the trigger coil. Trigger coil resistance should be
113-122Ω.
9. Check the green/white wire and blue/white wire separately for continuity to chassis ground.
10. If the trigger coil resistance is outside the specified range, or there is any continuity found in
step 9, replace the ignition coil/trigger assembly.
Black Ignition Wire
Ignition Coil
Red Ignition Wire
Ground Wire
Trigger Coil
6-Pin Connector
Fig. 20
Green/white Trigger Wire
Blue/white Trigger Wire
Fig. 19
Spark Plug Cap
31
PH3300i SM, Rev. 2017-01-20
4.4.3 Ignition Switch Inspection
■
Before beginning to test the ignition switch, make sure the batteries are fully
charged and the terminal connections are clean and tight (section 3.2).
1. Remove the control panel to gain access to the back side of the ignition switch.
2. Find the 6-pin ignition switch connector behind the control panel as shown (Fig. 21).
Disconnect it for the first part of the test.
3. In the OFF position there should be continuity (0Ω) between the black and pink wires only.
4. In the ON position there should be continuity (0Ω) between the red and orange wires only.
5. In the START position there should be continuity (0Ω)
Fig. 21
between the red, orange and blue wires only. If the
switch passes steps 3-5 then the ignition switch is good,
continue to step 6 to test the ignition wiring. If the switch
did not pass steps 3-5 replace the switch before
continuing.
6. Reconnect the ignition switch for steps 6-8. Refer to the
table below for the ignition wire voltages at the different
ignition switch positions. In the OFF position verify that
there is battery ground at the black and pink wires and
that there is 12V positive (battery voltage) at the red
wire.
7. Turn the switch to the ON position and verify that there
is battery ground at the black wire and no ground at the
pink wire. Verify that there is 12V positive (battery
voltage) at the red and orange wires.
8. Turn the switch to the START position and verify that
there is battery ground at the black wire and no ground
at the pink wire. Verify that there is 12V positive (battery
voltage) at the red, orange and blue wires (the starter should crank as well). If the switch has
passed steps 6-8 then the ignition switch and the ignition switch wiring are good. If the switch
passed steps 3-5, but failed one or more of steps 6-8 then look for a wiring problem in the
ignition switch circuits.
Wire Voltage at Different Switch Positions
Ignition Switch Position
Wire Color
OFF
ON
START
Black
0V (Gnd)
0V (Gnd)
0V (Gnd)
Red
12 (Batt+)
12 (Batt+)
12 (Batt+)
Orange
0V
12 (Batt+)
12 (Batt+)
Blue
0V
0V
12 (Batt+)
Pink
0V (Gnd)
0V
0V
32
PH3300i SM, Rev. 2017-01-20
4.5 Oil Level Sensor Fails to Stop Engine with Low Oil
Completely drain the oil, disconnect the
oil sensor wire connector, and check
the continuity between the white wire
and chassis ground (section 4.5.1).
Continuity
Follow step 1 in (section 4.13) to
access the voltage regulator. Check the
continuity of the white wire between the
low oil sensor (section 4.5.1, Fig. 23)
and the low oil sensor connector on the
voltage regulator (section 4.13, Fig. 30).
No continuity
No continuity
Check and repair all wire
connections as necessary.
Replace the oil level sensor if
necessary (section 5.7 and 5.12).
Repair or replace the wire
between the low oil sensor and
the voltage regulator.
Continuity
Verify that the voltage regulator supplies
12.5-14.5V to the ignition/indicator module
when the white wire of the voltage regulator
is grounded (section 4.13, step 6).
No or low
voltage
Replace the voltage regulator.
Good Voltage
Check the continuity of the pink wire
between the voltage regulator and the
ignition/indicator (section 4.13, step 6).
No continuity
Repair or replace the wires
between the voltage regulator
and the ignition/indicator module.
Continuity
If the voltage from the voltage regulator is
reaching the ignition/indicator module, and
the engine is not being shut down and/or
the low oil light is not being illuminated,
then replace the ignition/indicator module.
33
PH3300i SM, Rev. 2017-01-20
4.5.1 Checking the Low Oil Sensor
This generator is equipped with a low oil sensor that shuts down the engine when the oil reaches
critical levels, to prevent engine failure. The low oil sensor is mounted inside the crankcase of the
engine. If the oil sensor needs to be replaced, the crankcase will need to be opened. Refer to
(section 5.7) for engine removal and (section 5.12) for opening the crankcase.
1. Remove the maintenance door and locate the oil sensor lead which is strapped to the battery
wire harness below the in-line fuse between the battery and the air cleaner (Fig. 22).
2. Disconnect the low oil sensor while the engine is running (Fig. 23).
3. Ground the white wire from the regulator connector to the engine block, to verify that the
engine stops and the low oil light on the control panel illuminates. If the engine fails to stop, or
the low oil light fails to illuminate, refer to the flow chart in (section 4.5) to diagnose the
problem.
4. After confirming that the engine oil is at the proper level, test for continuity between the white
wire of oil sensor connector and the case of the engine (Fig. 24). No continuity indicates a
normal condition. If there is any continuity at all, replace the oil sensor.
5. Continuity (.1–1.0Ω) between the white oil sensor lead and engine when the oil is drained
from the engine indicates a normal condition. If there is high resistance, or no continuity
replace the oil sensor

Failure to replace a faulty oil level sensor can lead to permanent engine damage
or destruction if the engine runs low of oil.
Fig. 22
Fig. 23
Low Oil Sensor
Lead Behind
In-line Fuse
White Connector
to the Regulator
White Connector
to the Low Oil
Sensor
Fig. 24
Check Continuity
between the White
Oil Sensor Wire and
Ground
34
PH3300i SM, Rev. 2017-01-20
4.6 Engine Stops Running
Check the oil level (section 3.3).
Low oil
Fill the oil reservoir to the
proper level and restart the
engine.
Faulty
Replace the oil level sensor
(section 4.5.1).
Sufficient oil
Check the oil level sensor (section 4.5.1).
Sensor working
No fuel
Check fuel level.
Add fuel and restart the
engine.
Sufficient fuel
Blocked
Check the fuel valve, fuel filter (section
3.9), and fuel lines for blockage.
Clear the fuel valve and
lines, replace the fuel filter
(section 3.9).
Not blocked
Faulty
Check the fuel pump (section 4.6.1).
Replace the fuel pump
(section 4.6.1).
Normal
No/poor spark
Check for spark (section 4.4.1).
Test the ignition system
(section 4.4).
Good Spark
Abnormal
Check BFP solenoid (section 5.1.3).
Replace the BFP solenoid
(section 5.1.3).
Normal
Abnormal
Check the carburetor gasket for leakage.
Tighten carburetor bolts or
replace gasket as required.
Normal
Perform the throttle control system test
(section 5.1.2.2).
Abnormal
Replace step motor
(section 5.1.2.1).
Normal
Check trigger ignition coil/assembly
(section 5.8).
Abnormal
Normal
Measure the cylinder compression
(section 4.3).
Abnormal
35
Readjust the trigger clearance
(section 5.8).
1. Check the valve clearance (section 3.7).
2. Check head gasket.
3. Check for carbon deposits on the valves
& combustion chamber. Clean as
necessary.
4. Check the valve cone and seat (section
5.13.3). Lap valves, or replace & regrind
as necessary.
5. Check for worn piston, piston ring or
cylinder (section 5.14.4). Re-ring or
overhaul as necessary.
PH3300i SM, Rev. 2017-01-20
4.6.1 Fuel Pump Testing
This generator is equipped with a vacuum powered fuel pump that is mounted on a vertical frame
member behind the front cover (Fig. 25). The vacuum that powers the fuel pump comes from a
vacuum port on the insulator block between the carburetor and the engine. Before testing the fuel
pump verify that the vacuum hose from the isolator block to the fuel pump is in good condition
and has no leaks, blockages, or kinks. Replace the hose if necessary. Standard fuel line of the
same size may be used if the OEM replacement hose is unavailable.
1. Disconnect the spark plug wire so that the engine will not start while conducting this test.
2. Follow steps 1-6 in (section 5.1.1) to gain access to the fuel pump behind the front cover
(Fig. 25). Plug fuel lines as necessary.
3. Remove the fuel lines from the inlet and outlet of the fuel pump, but leave the vacuum
line attached.
4. Remove the screws that hold the fuel pump to the frame, and carefully allow the fuel
pump to hang in front of the inverter from its vacuum line.
5. Using two spare pieces of fuel line, 6-8” long, attach one on the inlet and one on the
outlet of the fuel pump (Fig. 26).
6. Find a small open container that will safely hold a few ounces of fuel to a depth of
0.5-1.0”. Put the fuel in it, and place it so the fuel line from the pump inlet is completely
below the surface of the fuel.
7. Hold the fuel line from the pump outlet over the edge of the container, so that any fuel
being pumped back into the container will be clearly visible.
8. Turn the ignition key to the START position and hold it there while watching the end of
the fuel line from the fuel pump outlet. Within 3-5 seconds there should be fuel flowing
back into the container in gentle pulses timed with the revolutions of the engine. This
indicates that the fuel pump is working properly.
9. If after 10 seconds of cranking there is no fuel present replace the fuel pump.
Fuel Pump
Inlet
Fuel Pump
Fig. 25
Fig. 26
To Vacuum
Port
Fuel Pump
Outlet
36
PH3300i SM, Rev. 2017-01-20
4.7 Engine Speed Cannot Increase or is Hunting
Blocked
Check the fuel filter, fuel valve, fuel lines,
and tank strainer for blockage or
restrictions.
Not blocked
Blocked
Check the air filter element for blockage.
Replace fuel filter (section 3.9). Clean
lines, valve, and strainer as necessary.
Clean the air filter element (section 3.5).
Not blocked
Blocked
Inspect spark arrestor for carbon buildup
(section 3.10).
Remove and clean carbon deposits
(section 3.10).
Not blocked
Remove and inspect the spark plug
(section 3.6). Check for spark
(section 4.4.1).
Normal
Abnormal
Check the carburetor for blockage
(section 5.1.1).
Blocked
Disassemble and clear (section 5.1.5, Fig.
43).
Abnormal
Replace vacuum lines or carburetor gasket
as required (section 5.1.1).
If spark is weak or erratic refer to
(section 4.4). Clean or replace spark
plug as necessary.
No blockage
Check the carburetor gasket and vacuum
lines for leakage.
Normal
Abnormal
Measure the cylinder compression
(section 4.3).
Normal
Perform the throttle control system test
(section 5.1.2).
1. Check the valve clearance (section 3.7).
2. Check head gasket.
3. Check for carbon deposits on the valves &
combustion chamber. Clean as necessary.
4. Check the valve cone and seat (section
5.13.3). Lap valves, or replace & regrind as
necessary.
5. Check for worn piston, piston ring or
cylinder (section 5.14.4). Re-ring or
overhaul as necessary.
4.8 Engine Speed Too High
This generator has been designed to prevent the engine from “overspeed” revving. Overspeed
revving occurs when a generator’s on-board monitoring systems detect a drop in voltage from the
inverter, and the generator attempts to compensate by revving the engine higher to generate more
electricity. In the rare event of an inverter failure, there will be no voltage output from the inverter, and
the engine will remain revving at or close to its top speed. In the event this happens, the engine will
be shut down by the overspeed protection. If the engine overspeeds and then shuts down, restart the
engine and check the AC output.
Abnormal
Check the AC output.
Normal
Check the carburetor gasket and
vacuum lines for leakage.
Normal
Check the throttle control step motor
(section 5.1.2.2).
“No or low AC output” and perform
the recommended diagnostics
(section 4.9).
Abnormal
Replace vacuum lines or
carburetor gasket as required.
(section 5.1.1).
Abnormal
Replace the throttle control step
motor (section 5.1.2.1).
Normal
Replace the inverter. (section 5.10.1).
37
PH3300i SM, Rev. 2017-01-20
4.9 No or Low AC Output
■
This generator is equipped with a low voltage shutdown feature. If conditions are
such that the engine begins to bog down before enough power is produced for
the inverter to overload, the voltage will begin to fall as the engine loses speed.
When this happens the low voltage protection will turn on the overload light, and
shutdown the inverter to protect delicate electronic equipment. When the inverter
has been shut down due to low voltage, it cannot be reset with the rest button on
the control panel. The unit must be shut down with the key and restarted to
restore AC power output.
Yes
Is the Overload Indicator light on?
No
Disconnect the load and press the
overload reset button. If the inverter fails
to reset, test reset button and wires to
inverter. If reset button and wires are OK,
replace inverter (section 5.10).
Tripped
Check all circuit breakers. Are any of
them tripped?
Not tripped
Disconnect the load and reset the
breakers.
Stop the engine and check the AC
receptacles for burnt contacts and loose
or burnt connections.
Abnormal
Replace the AC receptacles if necessary.
Normal
Engine
jammed
Check to see if the engine feels jammed
or seized upon being shut down.
Inspect the rotor magnets for damage,
replace the rotor if damaged (section 5.9).
Engine turns normally
Measure the stator output voltage while
running (section 4.10), and the stator
winding resistance (section 5.9.1).
Abnormal
Inspect and repair stator wire harness or
replace stator (section 5.9.2). Check
cylinder for foreign objects.
Normal
Replace inverter (section 5.10).
38
PH3300i SM, Rev. 2017-01-20
4.10 Measuring Stator Main Output Voltage While Running
■
Before conducting this test turn the ignition key ON and OFF. This will pre-set the
throttle in the proper position for starting the generator. This will prevent engine
overspeeding due to the throttle being left wide open during shutdown.
1. Remove the 6 control panel screws, carefully allowing it to hang out of the way.
2. Remove the maintenance door and disconnect the carburetor step motor connector. On some
models it is necessary to follow steps 1-7 in (section 5.1.1) because the step motor connector is
routed all the way to the inverter and cannot be accessed from the maintenance door.
3. Find and unplug the connector from the inverter and start the engine (Fig. 27). It will be
necessary to manually adjust the throttle to make the engine run in the upper RPM range
(3000-4000 RPM) before checking the stator main output voltage. Once set, do not alter the
throttle during the rest of the test.
4. Check voltage between pins 1 & 4, between pins 2 & 4 and between pins 1 & 2 (Fig. 28). There
should be approximately 180-300VAC at each test. The three readings should be approximately
equal within ±25VAC.
5. If one or more of the three tests fail, the problem is either a damaged wire harness or a defective
stator/rotor. Check the wire harness for damage, and repair and retest if necessary.
6. If it has been verified that there are no wiring issues, then the stator/rotor is faulty and will need to
be replaced. If all these tests are OK but there is still no or low voltage, the inverter will need to
be replaced (section 5.10.2).
To 120VAC
Output
To 6-Pin Stator
Connector
Fig. 27
Fig. 28
White Sub
Windings
3&6
6-Pin Stator
Connector
6
4
3
2
1
Black Phase Wires
1, 2 & 4
39
PH3300i SM, Rev. 2017-01-20
4.11 No DC Output At Battery Charge Receptacle
Abnormal
Check the DC circuit breaker.
Normal
Find the 9-pin connector from the voltage
regulator (section 4.13). With the
generator running, verify that there is
13-15V on the red-black wire (section
4.13, Fig. 28).
Abnormal
Reset DC circuit breaker if tripped. Check
continuity through breaker, replace if
faulty.
Inspect wires of the 9-pin connector from
the voltage regulator for breaks and
shorts (section 4.13, Fig. 28), and check
continuity through to the DC receptacle.
Repair as necessary. If there are no
wiring issues, replace voltage regulator.
4.12 Starting Battery Will Not Charge
Before troubleshooting, inspect battery
condition (section 3.2). Inspect the battery
terminals & quick disconnect
connections.
Abnormal
Charge battery using recommended
charger. Do a load test to make sure the
battery maintains adequate voltage under
load. Clean battery terminals. Replace
battery if necessary.
Abnormal
Check all wire connections of the voltage
regulator. Test the voltage (section 4.13).
Normal
Check the DC voltage at the battery and
the control panel with the generator
running. See steps 1 and 2 on the
following page.
Normal
With the generator running, unplug the
stator low voltage winding from the
voltage regulator. Measure the voltage
between the blue wires (section 4.4.3,
Fig. 21).
Voltage: 16-20VAC Normal
Abnormal
Check the wiring harness for breaks or
shorts, repair as necessary. If no wiring
issues found, replace the stator (section
5.8).
Replace the voltage regulator.
40
PH3300i SM, Rev. 2017-01-20
4.13 Voltage Regulator Testing
The voltage regulator provides three different isolated voltage sources. The first is the charging
voltage for the 12V starting battery, which uses the negative battery terminal and chassis ground as
its ground reference. The second is the 12VDC output for the control panel, which also uses chassis
ground as a ground reference. The third voltage is the charging voltage for the 3.6V Li-ion batteries,
which uses the black wire from the voltage regulator as a ground reference. In the following tests it is
important to measure the voltages between the wires designated in the test procedures. If chassis
ground is used as a ground reference in every test, then the voltage reading for the Li-ion battery
charging voltage, and the oil alarm signal, will be false readings.
1. To access the voltage regulator, follow steps 1-7 in (section 5.1.1). After conducting the
voltage regulator tests, reassembly using the steps in the reverse order.
2. With the generator running, unplug the stator low voltage winding from the voltage regulator.
Measure the voltage between the blue wires (Fig. 29). The voltage should be 16-20VAC. If
the voltage is good, reconnect the stator and voltage regulator and continue the test. If the
voltage does not fall within this range then replace the stator (section 5.9.2).
3. With the generator running and all voltage regulator connections connected, perform the
following steps:
a. Measure the starting battery charging voltage from the voltage regulator 9-pin connector
(Fig. 30). Put the voltmeter positive test lead on the red wire, and the negative test lead
on the yellow/green wire. The voltage should be 12.0-14.5 VDC, depending on the
condition of the starting battery. If the voltage does not fall within this range, replace the
voltage regulator.
b. Measure the control panel DC output voltage from the voltage regulator 9-pin connector.
Put the voltmeter positive test lead on the red/black wire, and the negative test lead on
the yellow/green wire. The voltage should be 13-15 VDC. If the voltage does not fall
within this range, replace the voltage regulator.
c. Measure the Li-ion battery charging voltage from the voltage regulator 9-pin connector.
Put the voltmeter positive test lead on the red/white wire, and the negative test lead on
the black wire. The voltage should be 3.7-4.2VDC, depending on the condition of the
Li-ion batteries. If the voltage does not fall within this range, replace the voltage regulator.
4. With the engine running, disconnect the low oil sensor connector to test the voltage regulator
low oil sensor response. Leave the 9-pin and stator connector connected. Put the voltmeter
positive test lead on the pink wire, and the negative test lead on the black wire of the 9-pin
connector. Using a jumper wire connect the white wire from the voltage regulator low oil
sensor connector to the engine block. The voltmeter should change from 0VDC to
12.5-14.5VDC, and the engine should die. If neither of these things happens, replace the
voltage regulator. If the voltage changes, but the engine does not die, then look for a break or
short in the pink wire between the voltage regulator and the ignition/indicator module on the
control panel. If the pink wire has good continuity, but the engine still does not die and/or the
low oil light does not illuminate when the white wire is grounded, replace the ignition/indicator
module.
Fig. 29
Low
Voltage
Windings
from
9-pin Connector To Wiring
Harness
Fig. 30
To the
Voltage
Regulator
To Low Oil
Sensor
To Stator
41
PH3300i SM, Rev. 2017-01-20
4.14 Engine Runs-on or Backfires After Being Turned Off
This generator is equipped with a backfire prevention solenoid (BFP) on the bottom of the carburetor
bowl that is activated to shut off the fuel for several seconds during shutdown. If the engine is
running-on or backfiring after being turned off the BFP system needs to be tested. Follow the
procedure below.
1. Remove the control panel and carefully let it hang from its connections.
2. Disconnect the BFP connector behind the control panel (section 5.1.3, Fig. 38).
3. Test for continuity between the green/white wire in the end of the BFP connector that goes back
into the harness and the green/white wire coming from the ignition/indicator module. If there is no
continuity you will need to repair or replace the green/white wire between the ignition/indicator
module and the BFP connector.
4. Test for continuity between the black wire in the end of the BFP connector that goes back into the
harness and the black wire coming from the ignition/indicator module. If there is no continuity you
will need to repair or replace the black wire between the ignition/indicator module and the BFP
connector.
5. Start the engine.
6. To test if the BFP is being activated after shutdown use a voltmeter and connect the positive lead
of the voltmeter to the green/white wire and the negative lead to the black wire of the end of the
BFP connector from the ignition/indicator module.
7. While the engine is running the voltage should be 0-1VDC. When the ignition switch is turned off
the voltage should read 12-14VDC for 1- 3 seconds. If the voltage does not go up to 12-14VDC
after the key is turned off, replace the ignition/indicator module.
8. If there were no issues found with continuity of the green/white or black wires, and the voltage
was 12-14VDC for 1- 3 seconds after shutdown, then test the BFP solenoid (section 5.1.3).
9. Replace the BFP solenoid if necessary (section 5.1.3).
4.15 Engine Will Start Then Shut Down
Low oil light
Check the low oil light.
No low oil light
If engine overspeeds briefly and then
shuts down and has no AC output;
then it is overspeeding due to inverter
failure.
Overspeeds
42
Check engine oil level. Sometimes the
oil level can be just above the critical
shutoff level before starting, and drop
below the shutoff level once started
due to oil splash. Add oil if necessary.
Replace the inverter (section 5.10).
PH3300i SM, Rev. 2017-01-20
5. REPAIR
5.1 Carburetor
5.1.1 Removal / Installation of Carburetor
■
Drain all gasoline from the fuel tank and
the carburetor (Fig. 31) before
disassembly.
■
Keep the unit away from all heat, flame
and sparks.
Fig. 31
1. Remove the maintenance door and disconnect the
battery.
2. Disconnect the manual choke cable from the carburetor
by loosening the screws shown in (Fig. 32). It is not
necessary to completely remove the screws.
3. Remove the control panel, carefully allowing it to hang out
of the way.
4. Disconnect the fuel hoses from the fuel valve, plug them if
necessary.
5. Remove the front lift handle.
6. Remove the six front cover screws and remove the front
cover. Carefully maneuver the control panel back through
the control panel hole in the front cover.
7. Remove inverter bolts and carefully lay the inverter on its
back.
Choke Cable
Hold-down
Screw
Fig. 32
Choke Cable
Adjustment
Screw
8. Remove the two screws from the air filter cartridge and
slide it out of the air cleaner.
9. Remove the two screws from the charcoal canister and
move it out of the way to gain access to the air cleaner.
10. Remove the six air cover screws, disconnect the Li-ion
battery connector, and take off the air cleaner cover.
11. Remove two nuts from the carburetor studs and remove
the air cleaner.
12. Disconnect the step motor connector.
13. Remove the carburetor as an assembly by sliding it off its
studs.
14. Reinstall the carburetor using these steps in reverse
order.
Fig. 33
Air Filter Cartridge
Air Cleaner Cover
Carburetor
Air Cleaner
43
PH3300i SM, Rev. 2017-01-20
5.1.2 Throttle Control – Step Motor
Remove and inspect the step motor if troubleshooting procedures have indicated it may be faulty.
Before removing the step motor, inspect the inside of the carburetor to make sure there are no
physical obstructions that would prevent the free motion of the throttle plate.
5.1.2.1 Removal / Installation of Step Motor
1. Remove the carburetor by following steps 1-13 in (section 5.1.1).
2. Unplug the step motor.
3. Take care not to dislodge the fork and fork spring located below the step motor
bracket (Fig. 35). The spring is under compression and can be easily lost if not
controlled. Remove the two step motor screws and carefully remove the step motor (Fig.
34). It is not necessary to remove the step motor bracket, or the choke cable mount, to
change the step motor. Leave the bracket and choke cable mount on, and hold the fork
and spring in place with a flat bladed screwdriver when pulling the step motor away from
its bracket.
4. Carefully align the flats on the shaft of the replacement step motor with the flats of the
fork (indicated by an arrow in (Fig. 35) when reinstalling the motor.
5. Reinstall the carburetor using the steps in (section 5.1.1) in reverse order.
Step Motor
Step Motor Bracket
Choke Cable Mount
Fig. 34
Choke Cable Mount Standoffs
Fork
Fig. 35
Fork Spring
44
PH3300i SM, Rev. 2017-01-20
5.1.2.2 Resistance and Backlash of Step Motor
Before checking the resistance, carefully rotate the step motor shaft back and forth between
your thumb and forefinger to check the backlash of the step motor gears. There should be
almost none. If the backlash is in excess of 0.25-0.38mm (0.010-0.015”) then replace the
step motor.
1. Measure the resistance of the outlet terminals of the step motor (Fig. 36).
Resistance value
Pin 1-blue - Pin 2-white:145-155Ω
Pin 3-red - Pin 4-black:145-155Ω
2. Replace the step motor if the resistance does not fall within the recommended range.
Fig. 36
1
3
2
4
45
PH3300i SM, Rev. 2017-01-20
5.1.3 Backfire Prevention Solenoid (BFP)
The backfire prevention solenoid is located on the bottom of the carburetor bowl. Its purpose is to
shut off the fuel when the engine is turned off to prevent post-shutdown backfire and run-on
(dieseling). If the backfire prevention solenoid is suspected of being faulty, measure the
resistance between the leads as detailed below.
1. Measure the resistance of backfire prevention solenoid between the two leads of the
green connector (Fig. 37). This connector can be accessed by removing the control
panel (Fig. 38).
2. To bench test the BFP solenoid drain the carburetor float bowl, unscrew the BFP and
remove it from the carburetor. The needle on the end of the solenoid should be in the
retracted position (Fig. 39). Apply +12V to one of the solenoid leads, and ground to the
other (polarity does not matter). The solenoid should make a click noise, and the needle
should move to the extended position (Fig. 39).
3. Replace the BFP if the resistance does not fall within the specified range, or it fails the
bench test. Make sure the end of the needle is clean before installing.
Resistance value
7-9Ω
Access BFP connector
behind control panel.
Measure resistance
between these pins.
Fig. 38
Fig. 37
Fig. 39
Extended
Retracted
46
PH3300i SM, Rev. 2017-01-20
5.1.4 Manual Choke Assembly
The manual choke is activated by a cable mounted on the front panel, next to the control panel,
and above the fuel valve. It has 4 positions; FULL (Fig. 42), ¾, ½, and OFF (Fig. 41). It is
mounted and adjusted properly from the factory, but the end of the cable attached to the
carburetor must be disconnected in order to take off the front panel.
Care must be taken when reconnecting the cable so it is
adjusted properly. If the cable is not adjusted properly the
choke may not be completely open in the OFF position, or
the choke may not be fully closed in the FULL position. If the
choke is not completely seated in its detent in the FULL
position, then the choke can wiggle off slightly during the
starting process. This can cause hard starting in extremely
cold conditions. Follow the procedures below for
disconnecting and reconnecting the choke cable.
Choke Cable
Hold-down
Screw
Fig. 40
Choke Cable
Adjustment
Screw
5.1.4.1 Disconnecting the Choke Cable
1. Remove the maintenance door and disconnect the
battery.
2. Disconnect the manual choke cable from the
carburetor by loosening the screws shown in (Fig.
40). It is not necessary to completely remove the
screws.
5.1.4.2 Reconnecting the Choke Cable
When reinstalling the front panel, make sure that the choke cable is routed so it is free, and
can be attached to the carburetor without restriction. Without a cable attached to the choke, it
is spring loaded in the OFF position (OPEN). It should be in this position at the start of this
procedure.
1. Thread the end of the choke cable through the cable hold-down and then through the eye
of the cable adjustment ferrule (Fig. 41).
2. Put the threaded fitting on the end of the choke cable case under the cable hold-down
until it firmly seats against the stop on the mount, see red circle in (Fig. 41). Tighten the
choke cable hold-down screw.
3. Push the choke knob down firmly and pull on the end of the cable to remove any slack.
Tighten down the choke cable adjustment screw. Verify the choke is still in the OFF
position (OPEN).
4. Pull the choke knob all the way out to the FULL choke position and verify that the choke
is fully closed (Fig. 42). Crank the starter, and pull the recoil starter several times while
carefully watching the choke to make sure the knob does not move and the choke
remains in the FULL choke position. If the choke moves off while cranking, adjust a very
small amount of slack from the cable and retest.
Choke Cable
Adjustment
Choke in OFF position
Ferrule
Choke in FULL position
Fig. 42
Fig. 41
Choke Cable
Hold-down
Screw
47
PH3300i SM, Rev. 2017-01-20
5.1.5 High Altitude Jet
The OEM jet that comes installed in the factory carburetor will provide optimal performance to an
altitude of 6000 feet. It is unnecessary to change to a high altitude jet for altitudes ≤ 6000 feet.
Fig. 43
Rubber Bowl
Seal
Emulsifier Tube
Fuel Bowl
Main Jet
O-Rings
BFP Solenoid
Fuel Bowl
Retainer
48
PH3300i SM, Rev. 2017-01-20
5.2 Control Panel
5.2.1 Disassembly / Installation
Fig. 44
Remove
Mounting
Screws (6)
Fig. 45
120V-20 &
30 amp
Circuit
Breakers
Ignition
Switch
12V DC Circuit
Breaker
Indicator
Module
Module Cover
12V
Receptacle
Hour
Meter
120V 20amp
Duplex (5-20)
120V 30amp
(L5-30)
Overload Reset
Button
49
Ignition
Key
USB
Ports
PH3300i SM, Rev. 2017-01-20
5.3 Outer Generator Housing
5.3.1 Disassembly / Installation
Gas Cap
Fig. 46
Fuel Gauge Sight Glass
Rubber Grommet
Rubber Grommet
Grommet
Top Cover
Gas Tank
Fuel Pump
Upper
Frame
Carbon Canister
Right Cover
Lift Handle
Oil Access Cover
Handle Sponge
Fold Over
Handle
Lift Handle
Exhaust
Grille
DC Voltage
Regulator
Starter Solenoid
Short Sponge
Rear
Cover Starting Battery
Front
Cover
Inverter
Choke
Knob
Fuel Knob
Left
Maintenance Cover
Door
Fixed
Wheels
Swivel
Wheels
50
Control
Panel
PH3300i SM, Rev. 2017-01-20
5.4 Recoil Starter
5.4.1 Disassembly / Reassembly
1.
2.
3.
4.
Remove the maintenance door and disconnect the battery.
Disconnect the manual choke cable from the carburetor (section 5.1.1, Fig. 32).
Remove the control panel, carefully allowing it to hang out of the way.
Disconnect the fuel hoses from the fuel valve, plug them if necessary.
5. Remove the front lift handle.
6. Remove the six front cover screws and remove the front cover. Carefully maneuver the control
panel back through the control panel hole in the front cover while removing it. Set the front
panel aside, and carefully allow the control panel to hang out of the way (Fig.47).
7. Remove inverter bolts and carefully lay the inverter on its back (Fig. 48).
8. Remove the three M6 flange bolts (circled in Fig. 48) and remove the recoil starter.
9. Reinstall all components in reverse order.
Fig. 47
Recoil Starter
Fuel Pump
Charcoal Canister
Inverter
Li-ion Batteries
Fig. 48
Recoil Starter
Inverter
51
PH3300i SM, Rev. 2017-01-20
5.5 Starter motor
5.5.1 Starter Testing
■
Before beginning to test the starter, make sure the battery is fully charged and the
terminal connections are clean and tight (section 3.2.1).
1. Follow steps 1-6 in (section 5.1.1) to remove the front panel.
2. Remove the rear end panel and the right side panel.
3. Disconnect the cable from the starter relay (Fig. 49).
4. Attach a 10 to 12 gauge jumper cable to the positive battery terminal of sufficient length to
reach the starter motor. It is important that the jumper wire be attached to the battery first and
not the starter so that any potential sparks that may be generated during this process are not
near the battery. Make sure the unconnected end of the jumper cable does not come in
contact with the chassis ground. Touch the unconnected end of the jumper to the starter
connection for the starter relay cable. The starter should engage the ring gear and turn the
engine at a normal cranking speed. If it fails to engage the ring gear, fails to crank or cranks
very slowly, or produces excessive heat or smoke, replace the starter (section 5.5.2).
5. If the starter passes step 4, reconnect the cable from the starter relay. Turn the ignition key to
the START position and verify that the starter performs as well as it did in step 4. If not, check
the cable from the starter relay for breaks, shorts or bad connections (section 5.6).
Cable from Starter Relay
Fig. 49
Starter
Motor
52
PH3300i SM, Rev. 2017-01-20
5.5.2 Starter Removal / Replacement
1. Follow steps 1-6 in (section 5.1.1) to remove the front panel.
2. Remove the rear lift handle and the rear end panel.
3. Disconnect the battery. Remove the right side panel. The recoil rope can be left in the hole in
the panel. Pull the rope, with the panel, very slowly until there is enough slack in the rope to
set the panel down out of the way.
4. Remove the cable coming from the starter relay.
5. Remove the three screws and two M6 bolts from the starter access cover and remove the
cover (Fig. 52). It may be necessary to remove the bolts holding the upper frame to the base
to allow the fuel tank to be moved up slightly to gain access to the bolt indicated with a dotted
circle. Also note that the cover is colored orange for the purposes of this manual, but is black
in production.
6. Remove the two M8 starter bolts (Fig. 53) and remove the starter. Slowly turn the engine, by
hand, through a full 360° turn, while examining the ring gear. If the ring gear has sections of
teeth badly worn or missing replace the rotor (section 5.9.2).
7. Replace the starter using these steps in reverse order.
Fig. 52
Fig. 53
M6 Intake
Fan Cover
Bolts
Cable from
Starter Relay
M8 Starter
Motor Bolts
#2 Phillips
Screws
53
PH3300i SM, Rev. 2017-01-20
5.6 Starter Relay
The starter relay is bolted to the chassis
next to the voltage regulator, behind the
inverter, and beneath the recoil starter, as
shown in (Fig. 54). Before beginning to
test the starter relay, make sure the
starting battery is fully charged and the
terminal connections are clean and tight
(section 3.2.1). Follow the 5 steps below
to gain access to the starter relay. The
starter relay can be tested on or off the
generator.
Fig. 54
Starter
Relay
1. Follow steps 1-7 in (section 5.1.1) for
removing the carburetor.
2. After conducting the starter relay
tests, re-assembly using the steps in the reverse order.
5.6.1 Testing Starter Relay on Generator
1. First verify that the starter relay has good chassis ground. The relay body is grounded
through its mounting bolts. Make sure the mounting bolts have good electrical contact with
the chassis. It may be necessary to remove the paint around the mounting hole to
accomplish this.
2. Verify that there is 12V positive (battery voltage) at the battery terminal of the starter relay
(Fig. 55). If not, clean battery connections or repair wiring as necessary to restore battery
power to the battery terminal. Verify that there is no continuity between the battery and
starter motor terminals of the starter relay.
3. Turn the ignition key to the START position. Verify that there is 12V (battery voltage) being
supplied to the spade terminal marked Start Wire from Ignition Switch in (Fig. 55). If there is,
the relay should make a single clicking sound, there should then be continuity between the
battery and starter motor terminals of the starter relay, and the starter is turning, the relay is
good.
4. If the ignition switch failed to supply 12V (battery voltage) to the relay then test the ignition
switch for the cause of the problem (section 4.4.3) and continue this test using a jumper wire.
Connect the jumper wire from the 12V positive terminal of the battery to the spade terminal of
the relay (from step 3). The relay should click, there should be continuity between the battery
and starter motor terminals, and the starter should be turning. If there is no continuity
between the battery and starter terminals, the relay needs to be replaced.
5. If there is continuity between the terminals but the starter fails to turn, check the wire between
the relay and the starter (Fig. 56) for breaks, shorts or dirty/loose connections. Repair as
necessary. If power is being supplied by the relay to the starter but the starter fails to operate
properly see (section 5.5) for starter service.
Fig. 55
Battery
Terminal
Cable from
Starter Relay
Starter
motor
Terminal
Fig. 56
Start Wire
from
Ignition
Switch
Starter
Motor
Chassis
Ground
54
PH3300i SM, Rev. 2017-01-20
5.6.2 Bench Testing the Starter 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 ¼” spade and the black negative lead to the metal
body of the relay (Fig. 57).
Resistance
4.9 - 5.9 Ω
2. Check the function of the start relay by connecting the ¼” spade terminal to the 12V positive
battery terminal. Connect the metal base or body to the negative battery terminal. There
should be a clicking sound as the relay is activated. While the relay remains activated, use
the volt-ohm meter to check continuity between the two lugs (Fig. 58). If there is no continuity
the relay is defective.
■ There must only be continuity between the battery and starter terminals when the
relay is activated.
Checking Resistance
Fig. 57
Checking Continuity
Fig. 58
Connect to 12V
positive battery
terminal
Connect to
negative battery
terminal
55
PH3300i SM, Rev. 2017-01-20
5.7 Intake Fan Cover
■
Drain all gasoline from the fuel tank before disassembly.
■
Keep the unit away from all heat, flame and sparks.
1.
2.
3.
4.
5.
6.
Follow steps 1-7 in (section 5.1.1) to remove the front panel and inverter.
Remove the charcoal canister.
Remove the rear end panel and the left and right side panels.
Remove the upper frame and the gas tank as an assembly (Fig. 59).
Disconnect all wires from the stator assembly.
Disconnect the starter motor wire and all ground wires.
7. Remove 4 nuts from the engine mounting bolts (2 on each side) and lift the engine assembly
off the base pan (Fig. 60 & 61).
8. Remove the carburetor and the intake fan cover, revealing the engine (Fig. 62).
Upper Frame and Gas Tank
Fig. 59
Fig. 60
Mounting Bolts
56
Fig. 61
PH3300i SM, Rev. 2017-01-20
Fig. 62
Intake Fan Cover Bolts
Intake Fan Cover Bolt
Intake Fan Cover Bolt
57
PH3300i SM, Rev. 2017-01-20
5.8 Ignition Coil/Trigger Assembly Adjustment / Replacement
1. Follow steps 1 through 8 as outlined in (section 5.7) (Intake fan cover).
2. Check the clearance between the trigger and the TDC block of the rotor by inserting a
feeler gauge (0.040”-0.060”) between them (Fig. 63). If the gap is correct there should be
only slight resistance felt when sliding the feeler gauge in between them. Adjust if
necessary (step 3).
3. Loosen the ignition coil & trigger mount bolts (circled in Fig. 63) and insert the feeler
gauge. Allow the magnetic tip of the trigger to contact the feeler gauge and retighten the
bolts. Recheck the gap, re-adjust if necessary.
4. Rotate the rotor to make sure there is no interference with any other components.
5. Reverse the procedure to reassemble.
1.0-1.2mm (0.040”-0.060”)
Trigger clearance
Fig. 63
Feeler
Gauge
Rotor
Trigger
Ignition
Coil
TDC Block
58
PH3300i SM, Rev. 2017-01-20
5.9 Stator and Rotor
5.9.1 Stator Inspection
1. Follow steps 1-7 in (section 5.1.1) for removing the front panel and inverter.
2. Locate the 6-pin harness (Fig. 64) near the inverter and unplug it.
3. Locate the two pin connector (Fig. 64) 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
0.20-0.60 Ω
Sub windings
Measure the resistance between the two sub winding terminals at the 6-pin connector.
White-White
Resistance
0.10-0.16 Ω
Main windings
Measure the resistance between each of the main winding terminals at the 6-pin connector (Fig. 64).
Black-Black-Black
Resistance
0.25-0.35 Ω
Fig. 64
6-Pin Connector from
Stator to 6-Pin harness on
Inverter
2-Pin Connector from
Stator to Voltage
Regulator
59
PH3300i SM, Rev. 2017-01-20
5.9.2 Stator Removal and Reassembly
■
Drain all gasoline from the fuel tank before disassembly.
■
Keep the unit away from all heat, flame and sparks.
1.
2.
3.
4.
5.
Follow steps 1-7 in (section 6.1) for removing the front panel and inverter.
Remove the rear end panel and left and right side panels (section 5.3).
Remove the upper frame and the fuel tank as an assembly (section 5.7, Fig. 59).
Disconnect all wires from the stator assembly.
Disconnect the starter motor wire and all ground wires, remove the starter (section 5.5.2, Fig.
52 & 53).
6. Remove 4 nuts from the engine mounting bolts (2 on each side) and lift the engine assembly
off the base pan (section 5.7, Fig. 60 & 61).
7. Remove the carburetor and the intake fan cover.
8. Remove the ignition coil/trigger assembly, starter cup and fan (Fig. 65).
9. Remove the M16 flange nut from the crankshaft (Fig. 65).
10. Attach an appropriate puller to the rotor using three M6X1 bolts (grade 8.8 or better) and
remove the rotor (Fig. 66).
11. Remove the cable retainer clip and 4 stator mounting bolts using an M5 Allen wrench (Fig. 67).
12. Reverse the procedure to reassemble.
Fig. 65
Stator
Stator
Bolts
Rotor
Flange Nut
Intake fan
Starter Cup
Ignition Coil/Trigger
Assembly
Fig. 66
Fig. 67
M6X1 Bolts
Cable Retainer
Clip and Bolt
60
PH3300i SM, Rev. 2017-01-20
5.10 Inverter Inspection / Adjustment / Replacement
The inverter is mounted near the front edge the base plate (chassis) between the frame uprights
behind the front cover. The performance specifications are given below. Check the inverter output at
the 120VAC receptacles on the control panel using a volt meter, and power meter or ammeter. If the
no/low load primary output voltage is out of range, or the inverter is overloading below the maximum
output, then the inverter needs to be adjusted or replaced. Note that replacement inverter output
should be checked as it may need minor adjustments before being put into service. Steps for the
adjustment and replacement of the inverter are detailed below.
Inverter Performance Specifications
Output Voltage (0-400W load)
118-124VAC, 58-62Hz
Rated Output (continuous)
3200W(30A)@108-132VAC, 58-62Hz
Maximum Output (for > 2 minutes)
3300W(33.3A)@108-132VAC, 58-62Hz
Minimum Output Before Overload
3350W(33.75A)@108-132VAC, 58-62Hz
5.10.1 Inverter Removal / Preparation for Adjustment
1. Follow steps 1-7 in (section 5.1.1) to remove the front panel and gain inverter access.
2. Carefully lay the inverter on its back (Fig. 68). If the inverter is being replaced, disconnect the
connections from the faulty inverter and connect the new one in its place. Set the inverter and
control panel on a flat, nonconductive surface as shown so there is no stress on the wires or
connections.
Fig. 68
Inverter, Ready
for Adjustment
Control Panel
61
PH3300i SM, Rev. 2017-01-20
5.10.2 Inverter Adjustment / Replacement


When setting the overload adjustment pot, the inverter will warm up rapidly due to
the lack of forced airflow. Do not run the unit for more than 5 minutes while
setting the overload adjustment pot. Have all your test equipment ready before
starting this step and conduct this adjustment expeditiously.
Only adjust the two adjustment pots referenced in these procedures. All other
adjustments are set at the factory and should not be adjusted under any
circumstances.
1. Complete steps 1-7 in (section 5.1.1) for removing the front panel and inverter.
2. Connect a volt meter to one of the 120V 20A duplex receptacles (5-20R). Connect a load
bank and power meter (or ammeter if you don’t have a power meter) to the 120V L5-30
receptacle.
3. Start the generator.
4. Adjust the voltage to 122V ±0.3 by turning the voltage adjustment pot screw (Fig. 70)
clockwise to increase and counter-clockwise to decrease.
5. Using a load bank and power meter set the overload adjustment pot (Fig. 71) to trip at
3350W - 3375W. Set it to trip at 27.9A – 28.1A if you are using an ammeter instead of a
power meter. Turn the adjustment screw clockwise to increase and counter-clockwise to
decrease.
6. Shut the generator off.
7. Seal the screws on both adjustment pots using a drop of touch up paint or silicone sealant.
8. Reassemble the generator using steps 1-7 in (section 5.1.1) in reverse order.
Voltage Adjustment Pot
Fig. 69
Fig. 70
Overload Adjustment Pot
Fig. 71
62
PH3300i SM, Rev. 2017-01-20
5.10.3 Inverter Ignition Power
The inverter supplies power to the ignition/indicator module for the CDI ignition system. During
normal running conditions the stator is providing the energy to the inverter for running the ignition
power. During start up the engine RPM may not be adequate to provide all the necessary energy,
so the inverter relies on the Li-ion ignition batteries and the starting battery for the necessary
energy to run the ignition power. It is still possible to start the generator without the help of the
batteries, but it requires a vigorous pull on the recoil starter to get sufficient engine RPM to get
the power from the stator.
When diagnosing a “no spark” condition, it may be necessary to verify that the inverter is
supplying the necessary power to the ignition/indicator module. The procedure for doing this is
below.
1. Follow the troubleshooting chart in (section 4.4) for diagnosing ignition problems. It is
important to have verified starting and Li-ion battery condition and proper operation of the
ignition switch and the low oil sensor before beginning this test.
2. Follow steps 1-7 in (section 5.1.1) to access the inverter. Lay the inverter down (Fig. 72).
3. Check the continuity from the red/white wire (Fig. 72) to the red/white of the
ignition/indicator module on the control panel. The resistance should be 0.1-1.0Ω. If the
resistance is not in this range then repair or replace this wire before continuing.
4. Check the continuity of the black wire from the Li-ion battery tray (section 3.2.2, Fig. 3) to
the 8-pin receptacle on the inverter shown in (Fig. 73). If the resistance is not 0.1-1.0Ω,
then repair the wiring to restore good ground to the inverter before continuing.
5. With the ignition key ON, put the positive test lead of the volt meter on the red wire (Fig.
72), and the negative lead on the black wire of the 8-pin connector on the receptacle (Fig.
73). Verify that the voltage is 3.2-4.2V. If there is no or low voltage refer to (section 3.2.2)
and (section 4.13) and restore good (battery voltage), or replace the voltage regulator as
necessary.
6. With the ignition key ON, put the positive test lead of the volt meter on the red/white wire
(Fig. 72), and the negative lead on the black wire of the 8-pin connector on the receptacle
(Fig. 73). Verify that the voltage is 12.5-14.0V. If there is no or low voltage replace the
inverter.
Check Black Ground Wire
from this 8-pin
Receptacle
Fig. 72
Fig. 73
Red Wire from
Voltage
Regulator/Li-ion
Batteries
Red/White Wire
to
Ignition/Indicator
Module
63
PH3300i SM, Rev. 2017-01-20
5.11 Muffler Removal / Replacement
■
Muffler removal and installation must be performed with the engine cold.
■
Drain all gasoline from the fuel tank before disassembly.
■
Keep the unit away from all heat, flame and sparks.
1. Remove the maintenance door and disconnect the battery.
2. Disconnect the manual choke cable from the carburetor by loosening the screws shown in (Fig.
32) of (section 5.1.1). It is not necessary to completely remove the screws.
3. Remove the control panel, carefully allowing it to hang out of the way.
4. Disconnect the fuel hoses from the fuel valve, plug them if necessary.
5. Remove the front lift handle, and then the six front cover screws. Remove the front cover.
Carefully maneuver the control panel back through the control panel hole in the front cover.
6. Remove the rear end panel, the side panels, and the top cover, reference the Outer Generator
Housing exploded view in (section 5.3).
7. Remove upper frame, with fuel tank, as one assembly (Fig. 74).
8. Remove the muffler cover bolts and remove the muffler cover (Fig. 75).
9. Remove the muffler bolts. Carefully note the placement of the various length bolts and spacers
during removal for reassembly (Fig. 76).
10. Remove the muffler. This gains access to secondary air valve and exhaust fan (Fig. 77).
Upper Frame and Gas Tank
Muffler
Cover Bolts
Fig. 75
Fig. 74
Gasket
Long
Spacer
M8x80
Exhaust Fan
M8x90
Fig. 76
Short
Spacer
M8x170
M8x150
64
Secondary
Air Valve
Fig. 77
PH3300i SM, Rev. 2017-01-20
5.12 Engine Exploded View
65
PH3300i SM, Rev. 2017-01-20
PH3300 Engine 177F
Ref
#
MFR #
Stock
1
03051419
--
Drain Bolt
2
03030167
--
Drain Bolt Gasket
3
09080501
--
Crankcase, 177F
4
09080506
69258
5
04030271
--
6
09070347
62512
M10 Serrated Flange Nut
7
09080509
69262
Low Oil Sensor
8
03050222
69351
M6 X 16 Flange Bolt, Zinc
9
09080518
61986
Connecting Rod Assy (Bolt M8 x 40)
10
09080518
61986
Connecting Rod Assy (Cap)
11
09080518
61986
Connecting Rod Assy (Rod)
12
09080503
61708
Crankshaft
13
07190223
64233
Bearing 6206
14
68183
69259
Oil Dipstick
15
09080552
69260
O-Ring, Dipstick
16
09080502
61614
Cover, Crankcase
17
04090021
69261
Oil Seal
18
03050225
69614
M8 X 35 Flange Bolt
19
09080514
61984
Piston Pin Clip
20
09080513
61899
Piston Pin
21
09080512
61760
Piston
22
09080517
61985
Piston Ring Set (5)
23
09080516
--
Second Piston Ring
24
09080515
--
Top Piston Ring
25
09080511
65113
Camshaft Assy
26
09080507
69266
Head Gasket
27
09080523
69267
Valve Lifter
28
09080522
61987
Valve Push Rod
29
03071201
--
30
09080530
69268
Intake Valve
31
09080531
69269
Exhaust Valve
32
03050627
--
33
09080504
69264
Cylinder Head
34
03050626
61698
Exhaust Manifold Stud
35
09080534
69558
Guide Plate
36
09070376-1
62475
Valve Adjusting Stud
37
09080525
69562
Rocker Arm
66
Description
Crankcase Gasket
Crankcase Pin
Pin, Cylinder Head
Stud, M8 X 106.5
PH3300i SM, Rev. 2017-01-20
38
09080524
62479
Adjustment Nut
39
09074014
69569
Valve Adjusting Jam Nut
40
09080521
69568
Valve Spring Washer
41
09080519
69561
Valve Spring
42
09070221
69564
Intake Valve Spring Retainer
43
09080520
69563
Exhaust Valve Spring Retainer
44
09080526
61988
Valve Adjustment Spacer
45
09080151
69537
Spark Plug, F7RTC
46
03050295
62489
M10 x 80 Flange Bolt
47
09080508
60554
Gasket, Valve Cover, 177F
48
092101031
65474
Cover, Valve
49
09070429
69263
Seal, Valve Cover
50
03030168
--
51
03050929
67106
67
Washer
Valve Cover Bolt, R1
PH3300i SM, Rev. 2017-01-20
5.13 Cylinder Head / Valves
5.13.1 Cylinder Head Removal
■
Drain all gasoline from the fuel tank before disassembly.
■
Keep the unit away from all heat, flame and sparks.
1. Follow steps 1-6 in (section 5.1.1) to remove the front panel.
2. Remove the rear end panel and the left and right side panels.
3. Remove the upper frame and the fuel tank as an assembly.
4. Remove the inverter (section 5.10.1).
5. Remove the air cleaner and carburetor (section 5.1.1).
6. Remove the intake fan cover (section 5.7).
7. Remove the muffler cover, muffler, exhaust fan, exhaust manifold and muffler case (Fig. 78, 79,
80).
8. Remove the upper and lower engine covers (Fig. 81).
9. Remove the valve cover and 4 - M10 head bolts (Fig. 82).
Muffler Cover
Muffler Case
Fig. 78
Fig. 79
Muffler
Fig. 81
Fig. 80
Upper Engine
cover
Exhaust
Manifold
Lower Engine
cover
Exhaust Fan
68
PH3300i SM, Rev. 2017-01-20
Fig. 82
Valve Cover
Cylinder Head
Bolts
Alignment
Sleeves
Valve Cover Bolt
and Rubber Seal
Valve Cover
Gasket
Cylinder Head
Head Gasket
5.13.2 Cylinder Head Disassembly and Reassembly
Fig. 83
Rocker
Arms
Rocker Arm
Studs
Valve Spring
Retainers
Push Rods
Cylinder Head
Intake Valve
Jam Nuts
Rocker Arm
Adjustment Nuts
Guide Plate
Lash Pad
69
Valve Springs
Exhaust Valve
PH3300i SM, Rev. 2017-01-20
5.13.3 Valve and Spring Inspection
● Free Length Of Valve Spring
Standard
39.1mm (1.54”)
Service limit
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
Intake valve
6.46-6.48mm (0.254”-0.255”)
6.40mm (0.252”)
Exhaust valve
6.45-6.47mm (0.254”-0.255”)
6.40mm (0.252”)
70
PH3300i SM, Rev. 2017-01-20
5.14 Crankshaft / Camshaft / Piston
5.14.1 Disassembly and Reassembly
Piston and Rod
Front Engine
Seal
Front Crankshaft
Bearing
Lifters
Key
Low Oil
Sensor
Crankshaft
Rod Bolts
Lower Rod Cap
71
PH3300i SM, Rev. 2017-01-20
5.14.2 Alignment of Timing Marks
■
Use marks to align camshaft gear and timing gear during installation.
Fig. 84
Timing Marks
Cam Gear
Crankshaft Gear
72
PH3300i SM, Rev. 2017-01-20
5.14.3 Camshaft Inspection
● Height of Camshaft
Intake/Exhaust
Standard
Service limit
31.70-31.78mm (1.248”-1.251”)
31.0mm (1.22”)
73
PH3300i SM, Rev. 2017-01-20
5.14.4 Piston / Connecting Rod
● Assembly of Piston Rings
■
Make sure the rings are installed with the
manufacturer’s label up.
■
Make sure the 1st ring and 2nd ring are not
interchanged.
■
Make sure the piston rings are free to move
after installation.
■
Stagger each piston ring gap 120° from each of the other rings.
74
PH3300i SM, Rev. 2017-01-20
● Cylinder Inner Diameter
Standard
Service limit
77.00-77.02mm (3.031”-3.032”)
77.10mm (3.036”)
● Piston Skirt Outer Diameter
Standard
Service limit
76.96-76.98mm (3.030”-3.031”)
76.85mm (3.026”)
10mm
● Side Clearance Of Piston Ring
Standard
Service limit
0.02-0.06mm (0.001”-0.002”)
75
0.15mm (0.006”)
PH3300i SM, Rev. 2017-01-20
● 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 (0.04”)
● Piston Ring Height
st
The 1 ring
The 2
nd
ring
Standard
Service limit
1.97-1.99mm (0.077”-0.078”)
1.87mm (0.074”)
1.97-1.99mm (0.077”-0.078”)
1.87mm (0.074”)
● Piston Pin Outer Diameter
Standard
Service limit
17.99-18.00mm (0.708”-0.709”)
17.95mm (0.707”)
76
PH3300i SM, Rev. 2017-01-20
● Piston Pin Hole Inner Diameter
Standard
Service limit
18.00-18.01mm (0.708”-0.709”)
18.05mm (0.711”)
● Connection Rod Small End Inner Diameter
Standard
Service limit
18.01-18.02mm (0.709”-0.709”)
18.08mm (0.712”)
● Connection Rod Big End Inner Diameter
Standard
Service limit
33.02-33.03mm (1.300”-1.300”)
33.1mm (1.30”)
77
PH3300i SM, Rev. 2017-01-20
● Crankshaft Neck Outer Diameter
Standard
Service limit
32.97-32.98mm (1.298”-1.298”)
32.9mm (1.29”)
● Connection Rod Big End Side Clearance
Standard
Service limit
0.1-0.4mm (0.004”-0.016”)
0.8mm (0.03”)
78
PH3300i SM, Rev. 2017-01-20
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POWERHOUSE Products
7930 S.W. Burns Way, Unit C
Wilsonville, OR 97070
PH3300i Service Manual, Rev. 2017-01-20
© DTS Manufacturing, All Rights Reserved.
www.powerhouse-products.com
79