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POWERHOUSE
POWERHOUSE POWER PRODUCTS
PH2100PRi SHOP MANUAL
Coast Distribution
April, 2011
®
1 PH2100PRI SM 04-27-2011
Preface
This manual covers the construction, function and servicing procedure of the
POWERHOUSE® PH2100PRi generator, certificated by CARB.
Careful observance of these instructions will result in better, safe service work.
All information, illustrations, directions and specifications included in this publication are based on the latest product information available at the time of approval for printing. Coast Distribution
Systems, Inc. reserves the right to make changes without incurring any obligation whatever. No part of this publication may be reproduced without written permission.
2 PH2100PRI SM 04-27-2011
CONTENTS
3 PH2100PRI SM 04-27-2011
4 PH2100PRI SM 04-27-2011
1. SPECIFICATIONS
1.1 SPECIFICATIONS
Dimensions and weights
Model
Overall Length
Overall Width
Overall Height
Net Weight, with battery
Engine
Model
Type
Displacement
Bore x stroke
Maximum horsepower
Compression ratio
Cooling system
Ignition system
Spark plug
Carburetor
Air cleaner
Governor
Lubrication system
Lube oil
Oil capacity
Starting system
Stopping system
Fuel used
PH2100PRI
22 in. (559mm)
11 in. (279mm)
19 in. (482mm)
73 lbs. (33kg)
152F
4-stroke,OVH, single cylinder, Gasoline engine
125cc
52.4Χ57.8 mm
4.35 Hp
9.2:1
Forced air-cooled
Electronic
A7RTC
Float type, Horizontal, butterfly valve type
Semi-dry type
Electronic control type
Pump
SAE 15W-40 (SF/SG grade or greater)
15.6 fl oz (460 ml)
Recoil starter / Electric / Remote
Primary circuit ground
Automotive unleaded gasoline
5 PH2100PRI SM 04-27-2011
Alternator
Alternator type
Alternator structure
Excitation
Phase
Rotating direction
Frequency regulation
1.2 CHARACTERISTICS
Model
Maximum output AC
Rated output AC
Rated output DC
Rated frequency
Rated voltage AC
Rated voltage DC
Rated current AC
Rated current DC
Power factor
Voltage variation rate Momentary
Average
Average time
Voltage stability
Frequency variation rate Momentary
Average
Average time
Frequency stability
Insulation resistance
AC circuit protector
DC circuit protector
Fuel tank capacity
Continuous running time at Rated load
~ 1/4 load
Noise level (Zero load to full load)
Multi pole rotation type
Self-ventilation drip-proof type
Self-excitation (Magnet type)
Single phase
Clockwise (Viewed from the generator)
AC-DC-AC conversion (Inverter type)
PH2100PRi
2.1KVA
2.0KVA
100W
60HZ
120V
12V
16.7A
8.3A
1.0cosφ
10%max.
1.5%max.
3 sec. max.
±1%
1%max.
1%max.
1 sec. max.
±0.1%
10MΩmin.
20A
10A
1.3 gal (4.9L)
3.0 ~ 7.5 hours
56~63 dB (A)/7m
6 PH2100PRI SM 04-27-2011
1.3 Wiring diagram
7 PH2100PRI SM 04-27-2011
2 Service Information
2.1 The importance of proper servicing
Proper servicing is essential to the safety of the operator and the reliability of the engine. Any error or oversight made by the technician while servicing can easily result in faulty operation, damage to the engine or injury to the operator.
Improper servicing can cause an unsafe condition that can lead to serious injury or death.
Follow the procedures and precautions in this shop manual carefully.
Some of the most important precautions are given below. However, we cannot warn you of every conceivable hazard that can arise in performing maintenance or repairs. Only you can decide whether you should perform a given task.
Failure to follow maintenance instructions and precautions can cause you to be seriously hurt or killed. Follow the procedures and precautions in this shop manual carefully.
2.2 Important safety precautions
Be sure you have a clear understanding of all basic shop safety practices and that you are wearing appropriate clothing and safety equipment. When performing maintenance or repairs, be especially careful of the following:
Read the instructions before you begin, and be sure you have the tools and skills required to perform the tasks safely.
Be sure that the engine is off before you begin any maintenance or repairs. This will reduce the possibility of several hazards:
a.) Exhaust gas contains poisonous carbon monoxide. Never run the generator in an enclosed area.
b.) Be sure there is adequate ventilation whenever you run the engine.
c.) The muffler becomes very hot during operation and remains hot for several minutes after stopping the engine.
d.) Let the engine cool before you touch it.
e.) Keep away from moving parts while the generator is running.
Do not run the engine unless the instruction tells you to do so. Even then, keep your hands, fingers, and clothing away.
Gasoline is extremely flammable and explosive under certain conditions.
To reduce the possibility of a fire or explosion, use caution when working around gasoline, use only a nonflammable solvent, not gasoline, to clean parts. Keep all cigarettes, sparks, and flames away from all fuel-related parts.
8 PH2100PRI SM 04-27-2011
2.3 Service rules
1. Use genuine POWERHOUSE® or POWERHOUSE®-recommended parts and lubricants or their equivalents. Parts that do not meet POWERHOUSE® design specifications may damage the engine.
2. Always install new gaskets, O-rings, etc. when reassembling.
3. When tightening bolts or nuts, begin with larger-diameter or inner bolts first and tighten to the specified torque diagonally, unless a particular sequence is specified.
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 ruin 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.
8. Follow the instructions represented by these symbols when they are used.
Electric precautions
1. Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire harness. To disconnect the locking connector, be sure to unlock first, and then disconnect.
2. Check the connector terminals for bent, excessive extrusion, missing terminal, or other abnormalities before connecting the connector.
3. To connect, insert the connector as full as it goes. If the connector is a locking type, be sure that it is locked securely.
4. Check the connector cover for breakage and check whether the connector female terminal is open excessively. Then, connect the connector securely. Check the connector terminal for rust.
Remove the rust using an emery paper or equivalent material before connecting the connector.
5. Set the harness clips in the specified places of the frame securely, and clamp the wire harnesses.
6. Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving parts and the hot parts.
7. Route and connect the wire harnesses properly. Be sure that the harnesses are not loose, twisted or pulled tight.
8. Route the wire harnesses properly so that they do not contact with the shape edges and corners, and the end of the bolts and screws on the body.
9. If a wire harness contacts the end of the bolts/screws or sharp edges and corners, protect the contact part of the harness with a tube or by winding with an electrician ‟s insulating tape. If the wire harness has a grommet, set the grommet securely.
10. Take care not to pinch the wire harnesses during installation of a part. If a wire harness has the damaged insulation, repair by winding with the electrician ‟s insulating tape.
11. Read the tester manufacture ‟s operation instructions carefully before operation with tester.
Follow the instructions of the Service Manual. Be sure that the battery built in a tester is fully charged and check the meter before inspection using the tester.
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2.4 Serial number location
The serial number can be found stamped on the engine block above the oil dipstick. It is visible when the maintenance panel is removed.
Serial
Number
2.5 Engine maintenance standards
Item Standard(mm)
Part
Engine
Cylinder
Piston
Piston pin
Piston ring
Maximum speed without load
1st ring
2nd ring
Oil ring
Sleeve I.D.
Skirt O.D
Pin bore I.D.
O.D
Height h
Ring side clearance
Ring end clearance
Width t
Height h
Ring side clearance
Ring end clearance
Width t
Height h
Ring side clearance
Ring end clearance
5000±100rpm
52.400-52.420mm
(2.0630
”~2.0638”
52.360-52.380mm
(2.061
”~2.062”)
15.002-15.008mm
(0.5907”~0.5908
14.994-15.000mm
(0.5903”~0.5905”)
0.97-0.99mm
(0.0381”~0.0389”)
0.02-0.06mm
(0.0008”~0.0024”)
0.15-0.25mm
(0.0059”~0.0098”)
1.90-2.10mm
(0.0748”~0.0826”)
0.97-0.99mm
(0.0381”~0.0389”)
0.02-0.06mm
(0.0008”~0.0024”)
0.15-0.25mm
(0.0059”~0.0098”)
2.0-2.3mm
(0.0787”~0.0905”)
1.85-1.96mm
(0.0728”~0.0771”)
0.03-0.18mm
(0.001”~0.007”)
0.20-0.50mm
(0.0078”~0.0196”)
Service limit
—
52.505mm
(2.0671
”)
52.25mm
(2.057
”)
15.05mm
(0.5925”)
14.95mm
(0.588”)
0.87mm
(0.0342”)
0.15mm
(0.0059”)
1.0mm
(0.039”)
1.80mm
(0.0590”)
0.87mm
(0.0342”)
0.15mm
(0.0059”)
1.0mm
(0.039”)
1.8mm
(0.0590”)
1.75mm
(0.0688”)
0.24mm
(0.009”)
1.0mm
(0.039”)
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Part
Connecting rod
Valves
Valve spring
Cam wheel
Stem O.D.
Guide I.D.
Seat width
Free length
Width t
Item
Small end I.D
Valve clearance
Outer spring
Inner spring
Cam height
Main jet
IN
EX
IN
EX
IN/EX
IN/EX
Carburetor
Spark plug
Float height
Pilot screw opening (Fixed)
Gap
Resistance
Primary side
Second side
Ignition coil
2.6 Motor
Part
DC winding
Sub winding
Main winding
Item Wire color
Resistance
Resistance blue－blue white－white
Resistance black－black－black
11
2.05-2.35mm
(0.0807”~0.0925”)
Standard(mm)
15.006－15.017mm
(0.590”~0.591”)
0.10±0.02mm
(0.0039” ± 0.0008”)
0.15±0.02mm
(0.0059” ± 0.0008”)
4.975-4.99mm
(0.1958”~0.1964”)
4.955—4.970mm
(0.1950”~0.1951”)
5.000—5.030mm
(0.197”~0.198”)
1.0mm
(0.039”)
35.5mm
(1.397”)
32.8mm
(1.291”)
29.026-29.086mm
(1.143”~1.145”)
0.75mm
(0.030
”)
12mm
(0.472”)
N/A
0.6
—0.7mm
(0.024”~0.028”)
0.045-0.070
Ω
5-8k
Ω
Standard( Ω)
120V
0.045~0.070
Ω
0.100~0.160
Ω
0.250~0.350
Ω
1.9mm
(0.0748”)
Service limit
15.08mm
(0.594”)
---
---
4.92mm
(0.1937”)
4.90mm
(0.193”)
5.06mm
(0.199”)
2.0mm
(0.079”)
33.8mm
(1.330”)
31.1mm
(1.224”)
28.5mm
(1.104”)
—
—
—
—
—
—
PH2100PRI SM 04-27-2011
2.7 Torque values
Item
Connection rod bolt
Spark plug
Crankcase cover
Flywheel nut
Standard torque
Specification
M10*1*13
M6*75
M12*1.25
M5 Bolt, nut
M6 Blot, nut
M8 Bolt, nut
Lbs-ft
Tightening torque
N·m
N/A
9.6~11
7.4-8.9
N/A
13~15
10-12
51.8-59.2
3.7~5.2
70-80
5-7
6~7.4
13.3~16.2
8-10
18-22
Note: Use standard torque values for fasteners that are not listed in this table.
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3. Trouble shooting
3.1 General symptoms and possible causes
Engine does not start or is hard starting
Fuel filter clogged
Fuel tank tube clogged
Fuel valve clogged
Carburetor faulty
Check valve / Choke pod
Ignition coil faulty
Spark plug faulty
Spark plug cap looses
Low oil sensor faulty
Replace
Clean
Clean clean
Inspect
Inspect
Inspect
Fix it securely
Inspect
Ignition module
Ignition winding faulty
Throttle opening fault
Inspect
Inspect
Set in fully close or half close position
Engine speed does not stabilize, too high or too low
Carburetor faulty
Economy switch
Throttle control motor (step motor) faulty
Inverter unit faulty
Valve clearance misadjusted
Disassemble and clean
Inspect
Inspect
Inspect and replace
Readjust
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3.2 Difficult cold starting
The choke on the PH2100PRi operates automatically. When the unit is off, the choke will return to the closed position. In some cases, the choke may close too slowly or open too fast. Both conditions can cause difficulty starting the unit. Read below to see if one or both conditions are present.
What to check:
1. Remove the maintenance cover to view the choke system (fig. 1-A).
2. Make sure that there is sufficient fuel in the tank and the fuel valve is open. If the unit has been sitting for some time or has been run out of fuel, it may be necessary to pump the primer bulb several times to fill the fuel filter, ensuring fuel is getting to the carburetor.
3. While cranking the engine over using the ignition key (Not the remote), watch the choke lever
(fig. 2-A). The lever should begin to move to the left (Open) position as it is being pulled by the vacuum from the engine.
Fig. 1
A
Choke opens too fast:
1. If the choke is being pulled open to fast, there will not be enough fuel drawn in to the intake manifold to start the engine. If after four starting attempts the unit fails to start, try holding the choke closed while cranking. If the unit now starts, shut the key off and allow the generator to cool down for several minutes. If after sitting for several minutes the unit is still hard to start without holding the choke closed, the check valve will need to be inspected. Air should flow easily in one direction only (Away from the choke pod). If air flows easily in both directions, replace the check valve.
Choke closes too slowly:
1. If the choke opens properly but does not return to the closed position over an extended period of time, restarting can be difficult. The choke should normally return to the closed position in 2 seconds or less. If the choke stays open for more than 5 seconds, the check valve will need to be replaced.
Fig. 2 Open Close
A
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3.3 Hard starting
Check the fuel level in the tank.
Sufficient fuel
Loosen the drain screw and check whether fuel reached the carburetor.
Good spark
Remove the spark plug and check for wet or fouled electrode.
Fuel not reached
Dry
Wet
No fuel
Install the spark plug and ground the electrode. Check the spark.
Good spark
No spark or weak spark
Low cylinder compression
Install a compression gauge in the spark plug hole and check the cylinder compression by pulling the recoil starter rope several times.
Add fuel and restart the engine.
Add fuel and restart the engine.
Check fuel filter, pump, fuel valve and for blockage in the carburetor port and nozzle.
Clean the electrode and restart, taking care that the choke is not closed too much. If flooding is severe, check the carburetor float valve.
Perform the ignition system troubleshooting.
1. Check the valve clearance
2. Check for carbon deposits in the combustion chamber.
3. Check for valve cone and base.
4. Check for worn piston, piston ring or cylinder.
Normal compression
Install the spark plug securely.
Restart the engine according to the starting procedure.
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3.3 Cylinder compression check
1. Remove the spark plug cap and spark plug.
2. Install a compression gauge in the spark plug hole.
3. Put the remote switch is on the OFF position.
4. Turn the ignition switch to the start position and measure the cylinder compression.
Cylinder compression 65 psi (0.45Mpa) 800rpm
Pressure
Gauge
Remote Switch
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3.4 Ignition system
Fill oil to the correct level.
Use A7RTC or equivalent spark plug.
Spark plug inspection
Don ‟t pull the recoil starter or turn the ignition switch to start while touching the high tension wire.
Turn off the fuel valve.
Pull the recoil starter several times to release the unburned gas in the cylinder with the engine switch OFF.
1. Remove spark plug.
2. Install spark plug cap.
3. Set the ignition switch to the “ON” position. Ground the negative (—) electrode (i.e. threaded part) of the spark plug against with a ground wire against the engine block, and pull the recoil starter rope to check the spark plug.
Ground Wire
Spark Plug
Spark Plug Wire
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Measure the spark plug gap and perform the spark plug test.
Standard clearance: 0.6-0.7mm
(0.024”- 0.028”)
No spark
Perform the spark test again using a new spark plug.
Good spark
No spark
Remove the control panel.
Perform the spark test using a new indicator module.
No spark
Good spark
Good spark
Check the ignition switch.
No spark
Disconnect the low oil sensor and perform spark test.
Good spark
Replace the spark plug.
Replace the module.
Replace the ignition switch.
Replace the low oil sensor.
No spark
Check the resistance of motor ignition winding.
Abnormal
Normal
Check the ignition coil resistance and high pressure cable, high pressure insulation cap.
Normal
Abnormal
Abnormal
Check ignition coil air gap.
Normal
Inspection or replace wire harness.
Replace the motor stator.
Replace the ignition coil.
Readjust air gap.
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3.5 Engine oil level is low, but engine does not stop.
Drain out oil completely, disconnect the oil sensor wire harness, and check the continuity between black wire and the chassis ground. (Page 33)
Continuity
No continuity
Check and repair all wire connections. Replace the oil level alarm
Ground the white lead from the indicator module to the engine block to ensure that the engine will stop when the low oil alarm lamp is lit. (Page 33)
No continuity
Repair or replace the wire harnesses
Continuity
Indicator module fault, replace the module.
3.6 Engine stops running (Throttle is in the correct position)
Check the oil level and oil sensor
Sufficient oil
Check fuel level
Sufficient fuel
Check the fuel valve and fuel filter for blockage
Not blocked
Check the fuel supply hose for blockage
Not blocked
Check the carburetor gasket for leakage
Normal
Perform the throttle control system test
Normal
Check ignition coil
Normal
Measure the cylinder compression
Oil sensor
No fuel
Blocked
Blocked
Abnormal
Abnormal Refer to step motor inspection section in service manual
Abnormal
Fill the oil reservoir to the proper level and restart the engine
Fill the tank with fuel and restart the engine
Clear the fuel valve and replace the fuel filter
Clear or replace the fuel supply hose
Tighten carburetor bolts or replace gasket as required
Readjust the coil clearance
Abnormal
1. Check the valve clearance
2. Check the carbon deposit
in combustion chamber
3. Check the piston, piston ring
and cylinder for damage
19 PH2100PRI SM 04-27-2011
3.7 Engine speed can’t increase or unstable (choke is at the correct position)
Check the air filter element for blockage.
Not blocked
Blocked
Inspect spark arrestor for carbon build up. Blocked
Clear the air filter element.
Remove and clean carbon deposits.
Not blocked
Remove the spark plug and check the electrode clearance for carbon deposit.
Normal
Check the carburetor and nozzle for blockage.
No blockage
Abnormal
Blocked
Abnormal Check carburetor gasket and carburetor heat insulation block.
Normal
Measure the cylinder compression.
Normal
Abnormal
Clear electrode, adjust clearance or replace the spark plug.
Disassemble and clear.
Screw the nut, and replace the papery gasket or heat insulation block.
1. Check the valve clearance.
2. Check the carbon deposit in combustion chamber.
3. Check the piston, piston ring and cylinder for damage.
Perform the throttle control system test.
3.8 Engine speed too high or too low
Check the AC output
Normal
Check the throttle control motor
Normal
Normal
Normal
Check the Economy switch
Check Economy switch connection wire
Replace the inverter unit
Abnormal
Abnormal
Abnormal
Perform the generator troubleshooting following the instruction of “No or low AC output”
Replace the throttle control motor
Replace the Economy switch
Abnormal
Repair or replace the wire harness
20 PH2100PRI SM 04-27-2011
3.9 Engine speed doesn ’t increase with economy system “ON” and a load connected.
Check the AC output.
Normal
Check the throttle control motor.
Normal
Check the Economy switch.
Normal
Check Economy switch connection wire.
Normal
Replace the inverter unit.
Abnormal
Abnormal
Abnormal
Abnormal
Perform the generator troubleshooting following the instruction of “No or low AC output”.
Replace the throttle control motor.
Replace the Economy switch.
Repair or replace the wire harness.
3.10 No or low AC output.
Is the overload indicator light ON?
ON
OFF
Is the engine speed normal?
Economy switch
ON: 2300±100 rpm
OFF: 5000±100 rpm
Abnormal
Normal
Stop the engine and check the AC receptacle.
Normal
Disconnect the 6P connector between the inverter and stator unit, pull the recoil starter with force, and measure the AC voltage between the black terminals and white terminal.
Black-Black-Black: ＞30V
White-White: ＞1V
Normal
Measure stator output with unit running.
Abnormal
Abnormal
Abnormal
Disconnect the load, and restart the engine.
Perform the throttle control system test.
Replace the AC receptacle.
1. Check and repair stator wire harness or replace stator.
2. Rotor inner magnetism decreases, replace the rotor.
Replace the stator.
21 PH2100PRI SM 04-27-2011
3.11 Measuring stator output voltage while running.
Inverter
6-Pin Stator
Receptacle
1
4
2 3
6
6-Pin
Stator
Connector
White Sub
Windings
3 & 6
Black Phase
Wires, 1, 2 & 4
1. Unplug the connector from the inverter and start the engine, check voltage between pins 1 & 4, between pins 2 & 4, and between pins 1 & 2. Note, the engine will be running at a high RPM.
2. They should be approximately 300vac at each test with the engine running at high speed. If one or more of the three tests fail, the problem is either a damaged wire harness or a defective alternator. If the wire harness is the problem, look for and repair the damage.
3. If the alternator is the problem, the stator will need to be replaced. If all three tests are OK, the problem is likely the inverter.
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3.12 No DC output at receptacle.
Is the engine speed normal?
Normal
Check the DC circuit breaker.
Normal
Check the DC output.
Normal
Check battery charge cables.
3.13 Battery will not charge.
Abnormal Perform the throttle control system test.
Abnormal
Reset DC circuit breaker.
Abnormal
Check the wire harness and all connections.
Abnormal
Replace Battery charge cables.
Check battery connections.
Normal
Check the DC output at battery.
Normal
Unplug the DC charge windings from the voltage regulator and measure the resistance.
Resistance: 0.3 Ω +/- 10%
Normal
Replace the voltage regulator.
Abnormal Clean and tighten all battery connections.
Abnormal
Check all wire connections of the voltage regulator.
Abnormal
Check the wire harness, or replace the stator.
To the
Voltage
Regulator
DC Battery
Charge
Windings from Stator
23 PH2100PRI SM 04-27-2011
3.14 Voltage regulator
Battery
Control
Panel
Harness
Ignition
Switch
Starter
Solenoid
Inverter
Chassis
Ground
Terminal
Voltage
Regulator
Stator
Starter
Solenoid
Chassis
Ground
Terminal
24 PH2100PRI SM 04-27-2011
3.15 Starter motor doesn’t run.
Measure battery voltage.
Normal
Check the 20A fuse at battery.
Normal
Check the ignition switch.
Normal
Check the starter relay.
Normal
Check the starter motor.
Normal
Check, repair or change main harness wire.
Abnormal
Abnormal
Abnormal
Abnormal
Abnormal
Charge battery.
Replace 20A fuse.
Replace ignition switch.
Replace the starter relay.
Replace the starter motor
.
Cable from
Starter
Solenoid
Starter
Motor
Terminal
Battery
Terminal
Starter
Motor
Start Wire from
Ignition
Switch
Voltage
Regulator
Solenoid
Chassis
Ground
25 PH2100PRI SM 04-27-2011
3.16 No output when operating in Parallel:
Abnormal Check whether the two generators could work well separately.
Is one of the over load indicating light on?
On
Off
Disconnect all loads and reset the inverter.
Normal
Replace parallel kit.
Perform single generator troubleshooting.
1. Check the parallel output cable
2. Check the parallel output terminal.
Turn “OFF” both generators and disconnect all the electrical devices from the generators.
Plug the cables from the parallel kit into each of the units.
Start both generators and confirm that both green "RUN" lights are illuminated. Note, the Economy Switch automatically turns off when
running in parallel.
Two separate PH2100PRi models can run in parallel to increase the total output to a maximum load of 4200 W (Rated output, 5200 W).
You can also run a PH2700PRi and a PH2100PRi in parallel. The maximum output will be 4200 W (Rated output, 4000 W).
Never Connect or Disconnect the parallel kit cables from the generators while running. Doing so will cause permanent damage
not covered under warranty.
The required output of the electrical appliance cannot exceed the rated output of parallel generators.
The special parallel cables for the PH2100PRi and PH2700PRi is only applicable to the parallel operation of two POWERHOUSE® generators.
This kit cannot be used for paralleling three or more generators or running two different brands of generators.
ONLY the POWERHOUSE® Dual Generator Parallel Kit and cables may be connected to the parallel signal port. DO NOT CONNECT TO
OTHER ELECTRONICS OR USE OTHER CABLES. Permanent
damage not covered by the warranty will occur.
26 PH2100PRI SM 04-27-2011
3-Pin Parallel
Cable ‘A’
3.17 Parallel operating procedure:
1. Prepare two POWERHOUSE® generators for operation.
2. Connect the 15-pin signal cable between the parallel kit and each generator and secure with the thumb screws.
3. Connect the 3-pin parallel cable from the parallel kit into each generator making sure that the cables for generator „A‟ and generator „B‟ are not switched.
4. Start both generators and confirm that both green "RUN" lights are illuminated on the generators and on the front panel of the parallel kit.
5. The Economy Switch may be used as long as the Economy switch setting of both generators is the same.
6. The starting procedure is the same as the normal starting procedure.
7. Securely plug the electrical appliance plug into either or both of the parallel receptacles and switch on the electrical appliance.
The required output of the electrical appliance cannot exceed the rated output of the generators. The special parallel cable for the PH2100PRI and
PH2700PRi is only applicable to the parallel operation of two POWERHOUSE generators. It cannot be used for paralleling three or more generators or
running two different brands of generators.
Be sure to only use parallel output cable for parallel operation.
Don't disconnect the parallel output cable during parallel operation.
3-Pin Parallel
Cable ‘B’
27 PH2100PRI SM 04-27-2011
20 and 30 amp Circuit
Breakers
Output Indicator
(Green)
120V Short
Indicator (Red)
Overload Reset
Button (Green) 120V-20 amp
Receptacle
120V-30 amp
Locking
Receptacle
Grounding
Terminal
To prevent electrical shock from faulty appliances, the parallel kit should be grounded. Connect a length of heavy cable between the parallel ground terminal and an external ground source.
1. During normal operating conditions, the output indicator lights (Green) will remain illuminated.
2. If the generators are overloaded (in excess of 4200W when using two PH2100PRi units) the overload indicator light (red) will flash slowly on only one generator. The indicator lights on the other unit and the parallel kit will all be off.
3. At this time, there will be no electrical output from the parallel panel and the connected appliance or load will be shut off.
4. Remove all electrical loads from the generators and/or parallel kit and then determine and correct the cause of the overload.
5. To reset the overload condition (Red light), press and release the (Green) overload reset button on the parallel panel. The (Green) indicator lights should be illuminated on both generators and on the parallel panel within 15 seconds.
28 PH2100PRI SM 04-27-2011
3.18 Troubleshooting Parallel Operation:
Problem Condition Cause Correction
Flashing overload
light.
The red overload light on one of the generators is flashing slowly.
There are no indicator lights on the other generator or parallel panel. There is no AC output from either of the generators or parallel panel. Both engines are running at a slow idle.
The load (Wattage) has exceeded the capacity of one or both generators.
Remove all loads from the parallel panel and the generators and press the green reset button on the parallel panel. The green indicator light on both generators and the parallel kit should come on within 15 seconds.
If the reset is pushed without correcting the cause for the overload, the system will try to reset briefly but the units will again shut down.
Repeatedly pressing the reset button without correcting the overload condition may cause permanent damage to the generators and/or parallel kit.
Short indicator light on the parallel panel
The red (Short) indicator light on the parallel panel is on. The indicator lights on both generators are all off. There is no AC output from either of the generators or parallel panel. Both engines are running at a slow idle.
The hot and neutral output wires between the parallel kit and appliances are shorted, or there is a short in the appliance.
Remove all loads from the parallel panel and the generators and check the appliances for shorts. Repair or replace shorted appliances as needed.
Press the green reset button on the parallel panel. The green indicator light on both generators and the parallel kit should come on within 15 seconds.
Repeatedly pressing the reset button without correcting the short circuit may cause permanent damage to the generators and/or parallel kit.
29 PH2100PRI SM 04-27-2011
3.19 Troubleshooting Parallel Operation (Cont.)
Problem Condition Cause Correction
No indicator lights (Red or Green)
There is no AC output from either of the generators or parallel panel. Both engines are running at a slow idle.
Loose or disconnected power cord between the parallel kit and parallel power socket on the generator.
Remove all loads from the parallel panel and the generators.
Reconnect or plug in the power cord from the parallel kit to the power socket on the generator. The green indicator light should come back on in approximately 15 seconds. If not, press the green reset button on the parallel panel.
No AC output from parallel panel
The green light on both generators and parallel panel are on. The generators are running at high idle.
An excessive load is connected to either the
30A or 20A receptacle on the parallel panel.
Remove or reduce excessive loads.
Reset circuit breakers.
30 PH2100PRI SM 04-27-2011
4. Maintenance schedule
4.1 Maintenance schedule
Item
Maintenance
Procedure
Check
Engine Oil
Change
Spark Plug
Spark Arrester
Check
Air cleaner
Fuel Filter
Valve clearance
Clean
Clean - adjust
Clean
Check
Replace
Check - adjust
Fuel tank & strainer Clean
O
O
Regular Service period (1). Perform at every indicated month or operating hour interval, whichever occurs first.
Each Use
First
Month
Or
4-6 HRS
Every 3
Months or
50 HRS
Every 6
Months
Or
100 HRS
Every Year
Or
300 HRS
O
O O
O (2)
O
O
O (2)
O (3)
O (2)
Fuel line Check Every 2-years (Replace as necessary) (3)
Note:
(1) For commercial use, operation hours are determined by proper maintenance.
(2) Service more frequently when operating in dusty areas, every 10 hrs or every day.
(3) Service by POWERHOUSE authorized agency, unless correct tools or professional specialist is available. Do service according to the manual.
31 PH2100PRI SM 04-27-2011
4.2 Checking the oil level.
Stop the engine and check the oil level, be sure to put the engine on a flat floor when checking.
1. Loosen the screw of the maintenance 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 to the edge of the oil filler port.
4.3 Changing oil
Drain the oil while the engine is still warm to assure rapid and complete draining.
Make sure to turn the engine switch and fuel lever OFF before draining.
1. Loosen the panel screw and remove the maintenance cover.
2. Remove the oil filler cap.
3. Install the oil drain pipe.
4. Drain dirty oil into a container thoroughly.
5. Refill with the recommended oil, and check the oil level.
6. Reinstall the access panel and tighten the screws securely.
Engine oil capacity: 15.6 oz (460 ml)
Drain
Pipe
Upper Level
Oil Fill Hole
Dip Stick
Upper Level
Lower Level
32 PH2100PRI SM 04-27-2011
Please dispose of used motor oil in a manner that is compatible with the environment and local disposal regulations. Do not throw it in the trash or pour it on the ground.
4.4 Checking for the low oil sensor
1. Remove the maintenance cover and locate the oil sensor lead which is below and too the right of the dipstick.
2. Disconnect the low oil sensor when the engine is running.
3. Ground the white lead (Female connector) from the indicator module to the engine block, to ensure that the engine will stop when the low oil alarm lamp is lit.
4. After insuring that the engine oil is at the proper level, test the continuity between the (Male connector) from the oil sensor and the case of the engine. No continuity indicates a normal condition.
5. Continuity between the oil sensor lead and engine when the oil is drained from the engine indicates a normal condition.
No continuity with the oil drained would indicate a faulty oil sensor or damaged wire that must be repaired or replaced. Failure to do so can lead to permanent damage if the engine runs low on oil.
Oil Sensor
Connector
Female Connector to module
Male
Connector
Check Continuity between the Male connector from the Oil sensor Lead and
Ground
33 PH2100PRI SM 04-27-2011
4.5 Air Filter
Inspection/Cleaning:
1. Loosen the panel screw and remove the side maintenance panel.
2. Remove the three air filter retaining screws. Remove the air cleaner cover and check the element. Clean or replace the element if necessary.
3. Wash the element in a non-flammable or high flash point solvent and dry it thoroughly.
4. Soak element in clean engine oil and squeeze out the excess oil.
5. Reinstall the air cleaner element and the air cleaner cover. Tighten the cover screws securely.
6. Reinstall the maintenance panel and tighten the screw securely.
Maintenance
Cover
Air Cleaner
Cover
Air Cleaner Case
Air Cleaner
Element
Air Cleaner
Cartridge
A dirty air cleaner will restrict air flow to the carburetor, reducing engine performance. If the engine is operated in dusty areas, clean the air cleaner more often than specified in the Maintenance Schedule.
Never run the engine without an element or the filter is damaged, as it will do great harm to the engine.
34 PH2100PRI SM 04-27-2011
4.6 Spark plug
Inspection/Cleaning:
1. Remove the spark plug cap and remove the spark plug.
2. Remove carbon or other deposits with a plug cleaner or stiff ire brush. Check the sealing washer for damage.
3. Measure the plug resistance; replace the spark plug if the measurement is not within the value shown.
Spark plug resistance 3~9KΩ
4. Measure the plug gap with a wire-type feeler gauge. Adjust by bending the side electrode
Spark plug clearance
Standard spark plug
0.6~0.7mm
(0.024”~0.028”)
A7RTC
0. 6- 0. 7
5. Install the plug finger tight to seat the washer, and then tighten with a plug wrench.
Torque valve is 9.6~11 lbs-ft (13~15 Nm)
35 PH2100PRI SM 04-27-2011
4.7 Valve clearance
Valve clearance inspection and adjustment must be performed with the engine cold.
Inspection/Adjustment:
1. Disconnect the battery.
2. Drain all fuel from the tank and carburetor.
3. Remove front and rear panels.
4. Remove the left and right covers.
5. Remove fuel tank.
6. Remove the carburetor assembly.
7. Remove the starter motor.
8. Remove the carbon canister.
9. Remove front and back engine covers.
10. Remove muffler.
Valve
Cover
11. Turn the rotor to set the piston at top dead center of the compression stroke.
The timing mark of camshaft should be vertical to the cylinder head seal, check whether the inlet and exhaust valve are closed.
Timing
Mark
36 PH2100PRI SM 04-27-2011
Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance.
Valve clearance
IN
EX
0.10+/- 0.002mm
(0.0039” ± 0.0008”)
0.15 +/- 0.002mm
(0.0059” ± 0.0008”)
12. If adjustment is necessary, proceed as follows.
a. Loosen the adjusting screw lock nut and adjust the valve clearance by turning the adjusting screw in or out.
b. Secure the adjusting screw with a socket wrench and tighten the lock nut to the specified torque.
c. After tightening the lock nut, check the valve clearance again.
13. Clean the cylinder block and cylinder head cover.
Feeler Gauge
14. Replace the rubber seal.
15. Install the removed parts in the reverse order of removal.
Adjustment
Screw
Lock Nut
Rubber
Seal
37 PH2100PRI SM 04-27-2011
4.8 Fuel tank
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately.
Cleaning:
1. Disconnect the battery.
2. Drain all fuel from the tank and carburetor.
3. Remove front and rear panels.
4. Remove the left covers.
5. Remove all hoses from tank and clean it with cleaning solvent and allow the fuel tank to dry thoroughly.
6. After cleaning reconnect all hoses.
7. Install the removed parts in the reverse order of removal.
Fill the fuel tank with gasoline and check the fuel hoses for gasoline leaks.
4.9 Evaporation Control
Fuel Tank Vent
To Air
Filter
Carbon Canister
Air Filter
Assembly
Fuel Tank
38 PH2100PRI SM 04-27-2011
4.10 Fuel pump, primer bulb
Gasoline is highly flammable and explosive. You can be burned or seriously injured when handling fuel. Keep heat, sparks, and flame away. Wipe up spills immediately.
1. Disconnect the battery.
2. Remove front and rear panel.
3. Remove the left cover.
4. Drain all fuel from the tank and carburetor.
5. Check the fuel tubing for deterioration, cracks and gas leaks. If there is any abnormality in the fuel tubing, replace it.
6. Check the primer bulb and diaphragm tube for deterioration, crack or gas leaks. If there is any abnormality in the primer bulb or diaphragm tube, replace it.
7. Check to see whether water or foreign material has accumulated in the fuel pump.
8. If there is water or foreign material accumulated in the pump, replace the fuel pump.
9. Check the fuel valve and make sure there is no obstruction when open. Clean or replace as required.
10. After reassembly check all hoses and connections for fuel leaks.
Fuel
Valve
Primmer Bulb
To Intake manifold
To Carburetor
To Gas
Tank
Fuel
Pump
39 PH2100PRI SM 04-27-2011
5 Muffler system
5.1 Spark arrestor
Do the performance after engine has cooled completely.
1. Remove the four M6 screws and remove the muffler grill.
2. Remove the two M4 screws holding the spark arrester to the muffler.
3. Use a stiff wire brush to remove carbon deposits from the spark arrester screen.
4. Inspect the screen for holes, and replace it if necessary.
Spark Arrestor
M4 Screws
Muffler Grill
M6 Screws
40 PH2100PRI SM 04-27-2011
Muffler removal/installation must be performed with the engine cold.
5.2 Muffler
Disassembly/Reassembly
1. Disconnect the battery.
2. Drain all fuel from the tank and carburetor.
3. Remove front and rear panel.
4. Remove the left and right cover
5. Remove fuel tank.
6. Remove the carburetor assembly.
7. Remove the carbon canister.
8. Remove the starter motor.
9. Remove front and back engine covers.
Muffler gasket
Exhaust
Manifold
Muffler
41 PH2100PRI SM 04-27-2011
5.3 Exhaust tube, secondary air valve
Disassembly/Reassembly
1. Disconnect the battery.
2. Remove front and rear panel.
3. Remove right cover
Secondary
Air Valve
42 PH2100PRI SM 04-27-2011
6. Carburetor
6.1 Disassembly/Installation of Carburetor
Turn fuel lever to the “OFF” position.
Keep heat, flame and sparks away.
1. Disconnect battery.
2. Remove maintenance panel.
3. Disconnect the right vent hose from the carbon canister.
4. Drain fuel from carburetor.
5. Remove two carburetor mounting bolts.
6. Remove the carburetor, choke and air filter as an assembly being very careful not to pull on the step motor wires.
Choke Pot
Mounting Bolts
Right Canister Hose
43 PH2100PRI SM 04-27-2011
6.2 Disassembly/Installation of Step motor
步进电机机盖 from the throttle lever.
油门杆
Throttle level
44 PH2100PRI SM 04-27-2011
6.3 Disassembly/Installation of Carburetor
Mixed ratio adjusting
混合比调节螺丝
(Not adjustable on
出厂前位置已确
Emulsifier tube
Installation: clear the foreign matters with compressed air before
组装： installation. Pay attention to
先用压缩空气清除通 the installation direction
路中的脏物再安装。
注意安装方向。
主量孔
Main jet Installation:
先用压缩空气 with compressed air before
脏物再安装。 the installation direction
浮子
组装：
安装后应当用手指触
Float
动，对其动作确认。
Needle seat
针座
控油针
Installation: check the end and
作进行检查，再进行安装。
Drain screw
Installation: check the fuel leakage before
安装后确认没有燃油
45 PH2100PRI SM 04-27-2011
6.4 Step motor
Make sure to check the step motor connection on the inverter for any debris, damaged or bent pins
Measure the resistance of the step motor lead-out wire.
Replace the step motor if the resistance exceeds the ranges shown below.
Standard 1-blue ~ 2-white： 50~55Ω resistance 3-red ~ 4-black： 50~55Ω
1 2
3 4
46 PH2100PRI SM 04-27-2011
6.5 Automatic choke inspection/adjustment.
The choke on the PH2100PRi operates automatically. When the unit is off, the choke will return to the closed position
1. The automatic choke consists of the backpressure check valve and the vacuum pot, figure 1.
2. Items to check if the automatic choke fails to operate.
a. Check all vacuum hoses for cracks or damage, replace as necessary.
b. Check the backpressure check valve for leaks or a defective diaphragm.
c. Check all choke linkage to insure it operates smoothly and that the choke closes and opens fully.
d. To insure that the choke is closing fully, remove the filter and check the choke. Loosen the set screw and make sure that the butterfly closes completely, then retighten the set screw.
e. To check the vacuum pot for leaks, disconnect the vacuum hose from the barbed fitting.
Move the choke lever to the open position and block off the barbed fitting on the choke pot, figure 2. The choke should stay in the open position as long as the fitting is closed off.
Fig. 1
Choke Pot
Choke Cable
Vacuum Hose to
Manifold
Check valve
Close
Set Screw
Fig. 2
Barbed Fitting
Open
47 PH2100PRI SM 04-27-2011
7. Control panel
7.1 Disassembly/Installation
1. Remove six M4 panel screws.
Ignition
Switch
120V~20A
Circuit
Breaker
120V~20A
Duplex
Parallel Power Socket
Parallel Signal
Port
Indicator Module
DC Circuit
Breaker
48
Module Cover
Button Guard
Stop / Reset
Buttons
Covers
DC Battery
Charge
Receptacle
Economy / Remote
Switches
PH2100PRI SM 04-27-2011
8. Outer generator housing
8.1 Disassembly and installation of housing case
Spark Plug
Access
Exhaust Grill
Maintenance
Cover
Inverter
Left Case
Fuel Lever
Battery Access
Cover
49
Fuel Pump
Primmer Bulb
Fuel Valve
PH2100PRI SM 04-27-2011
Right Case
Panel Frame
Control Panel
9. Recoil starter / Electric Starter / Ignition coil
Caution
■ Drain all gasoline from the fuel tank before disassembly.
■ Keep the unit away from all heat, flame and sparks.
9.1 Recoil starter/Disassembly/Reassembly
1. Disconnect the battery.
2. Remove front and rear panels.
3. Remove the left and right covers.
4. Drain all gasoline from the fuel tank.
5. Remove the fuel tank and the inverter.
6. Remove (3) M6 flange bolts and the recoil starter.
7. Reinstall the inverter side covers and end panels.
Battery Box
Inverter
50 PH2100PRI SM 04-27-2011
9.2 Starter motor
● Disassembly
1. Disconnect the battery.
2. Remove front and rear panels.
3. Remove the left and right covers
4. Using and 8mm socket remove 2-mounting bolt.
5. Remove the starter and the cable.
Starter
Relay
Mounting Bolts
Cable
Screw
51 PH2100PRI SM 04-27-2011
9.3 Starter solenoid
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.
Resistance 4.6-6.0 Ω
2. Check the function of the start relay by connecting 12 volts + to the ¼” spade terminal and 12 volts negative to the metal base or body. There should be a clicking sound as the relay is activated. While the relay remains activated, use the volt ohm meter check continuity between the two lugs. If there is no continuity the relay is defective.
3. Note, there must only be continuity between the battery and the starter terminals when the relay is activated.
Checking Resistance
Checking Continuity
Connect 12volt
Negative.
Connect 12volts +
52 PH2100PRI SM 04-27-2011
9.3 Ignition coil
Inspection
1. Remove the control panel and locate the 2-pin primary coil plug with a Blue and Black wire and unplug it from the control panel.
2. Attach the two leads of tester to the Blue and Black wires and measure the primary resistance of the ignition coil.
3. If there is no resistance, check for continuity between the black wire and chassis ground. If there is no continuity repair or correct as necessary.
4. Replace the coil if there is no resistance or the value is outside of the values shown.
Primary resistance
1. Check continuity between the blue and black wires if installed.
2. If not Installed, check continuity between the blue wire and coil bracket.
0.045-0.070 Ω
Check the secondary resistance between the blue wire and spark plug cap
The black ground wire should be connected to the
Coil Bracket
The blue wire should be connected to the coil
5. To check the secondary resistance, attach one lead of the tester to the black wire of the primary plug of the ignition coil and the other lead to the spark plug cap.
6. If there is no resistance remove the spark plug cap and check the lead itself.
7. Replace the spark plug cap or coil if there is no resistance or the value is outside of the values shown.
Secondary resistance 5-8 k Ω
53 PH2100PRI SM 04-27-2011
9.4 Ignition coil/Disassembly
1. Disconnect the battery.
2. Remove front and rear panel.
3. Remove the left and right cover
4. Remove the fuel tank and the inverter.
5. Remove the inlet fan cover.
9.5 Adjustment
1. Adjust the clearance between the ignition coil and the outer magnet trigger of the rotor.
2. Loosen the ignition coil bolts and Insert a feeler gauge between the ignition coil and the permanent magnet of the rotor, (Both sides need to be adjusted equally) and retighten the bolts.
3. Rotate the rotor to make sure there is interference with the flyweights.
Ignition coil gap
Ignition Coil
0.5~0.75mm
Rotor
Permanent magnet
54 PH2100PRI SM 04-27-2011
10. Rotor/Stator disassembly / reassembly
10.1 Disassembly/Reassembly
1. Remove the following parts:
Front cover, control panel.
Rear cover.
Right/left side covers.
Fuel tank.
Battery box.
Inverter.
Fan cover
Starter cup and fan
M12 flange nut
Ignition coil
Rotor
M5 Stator bolts
Stator
Ignition Coil
Stator Assembly
Rotor
Assembly
M5
Flange Bolts
M12
Flange Nut
Fan
Starter cup
55 PH2100PRI SM 04-27-2011
10.2 Stator Inspection
(1) DC charging winding
Measure the resistance between the two blue terminals.
Resistance
Blue-Blue
0.045~0.070
Ω
(3) Sub winding
Measure the resistance between the two sub winding terminals.
Resistance
White-White
0.100~0.160
Ω
(4) Main winding
Measure the resistance between each of the main winding terminals.
Black-Black-Black
Resistance
0.250~0.350
Ω
Main Windings,
(Black)
Sub
Windings,
(White)
DC Battery
Charge Windings,
(Blue)
56 PH2100PRI SM 04-27-2011
11. Exploded engine view
57 PH2100PRI SM 04-27-2011
152 Engine
Item No.
1
2
2-1
3
4
5
6
7
8
9
10
11
23
24
25
26
27
28
Description
M6 x 75 hex screw
Front engine cover
Front seal
M8 nut
Chain for oil pump
Chain wheel for oil pump
M6 x 25 bolt
Oil pump
Crankcase gasket
Crank case bushing
Front crankcase
Oil passage cover
17
18
19
20
21
22
12 M3 x 5 roundhead screw
13 Oil dipstick
13-1 O'-Ring, dipstick
14
15
16
Crankshaft
Crankcase gasket
Crankcase bushing
M5 x12 bolt
O'-Ring, Low oil sensor
Low oil sensor
Rear crankcase
"O" style sealing ring
Tie bar bolt
Rear oil seal
Timing chain guide, tensioner
Timing chain
Timing chain guide
Retainer ring
Locating pin for piston
Mfg No
03050611
76115
040906-07
03060115
09070116
09070117
03050241
09070115
09070164
04030265
76113
09010342
03050802
68150
9070202
09070126
09070164
04030265
03050221
09070147
71046
76114
09070129-31
03050313
040906-07
09070111
09070112
09070109
09070139
09070102
69796
69309
69437
69351
69328
69706
69715
Stock No. Qty
7
69700
69709
1
1
1
69710
69712
69349
69714
69694
1
1
1
2
1
1
2
1
69701
69701
69705
69708
1
1
1
1
1
2
1
1
1
2
3
1
1
1
1
1
2
1
58 PH2100PRI SM 04-27-2011
152 Engine
Item No.
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
Description
Piston
Cylinder gasket
Locating bushing, head
M8 x 195 threaded stud
M8 x 185 threaded stud
Cylinder sleeve
Locating bushing, head
Head gasket
Intake valve
Cylinder head
Spark plug, A7RTC
M6 X 5 roundhead bolt
M6 x 20 bolt
Tensioner
Gasket, tensioner
44
45
Exhaust valve
Washer
09070123
09070121
46 Valve seal 09070118
47 & 48 Valve spring Kit, 2100 & 2700 09070120
49 Valve seat retainer 09070119
50
51
52
Lock catch for valve
M6 x 100 bolt
Camshaft
09070125
03050226
09070128
55
56
57
53, 54,
58 & 59
60
Rocker subassembly
M8 nut
Valve cover gasket
Valve cover/PCV Assy.
M6 x 25 bolt
09070133
03060115
09070110
77050
03050241
Mfg No
09070101
09070165
04030264
03050603
03050601
09070105
04030264
09070107
09070122
09070106
09080114
03050327
03050223
09070113
09070114
69670
69674
69675
69677
69681
69682
69669
69644
69709
69667
Stock No. Qty
1
69695 1
2
2
69685
69683
69684
69412
69686
69352
69688
69690
1
1
1
2
1
1
2
1
2
1
1
4
2
1
1
1
1
2
2
1
4
1
Need
69349
1
4
59 PH2100PRI SM 04-27-2011
12. Valve cover/ Rocker arm
12.1 Disassembly/ Reassembly
Remove the four bolts and valve cover.
1. Turn the rotor to set the piston at top dead center of the compression stroke.
2. The timing mark of camshaft should be vertical to the cylinder head seal, check whether the inlet and exhaust valve are closed.
3. Remove 4- rocker arm nuts and washers and carefully remove the rocker arm assembly
Timing
Mark
Alignment
Sleeves
60 PH2100PRI SM 04-27-2011
12.2 Rocker Arm Inspection
● Rocker arm outer diameter
Standard
9.96
—9.97mm
(0.3920.393”)
Service limit
9.953mm
( 0.391”)
● Rocker arm inner diameter of inlet/exhaust valve
Standard
10.000-10.015mm
(0.39360.3942”)
Service limit
10.040mm
( 0.3952”)
61 PH2100PRI SM 04-27-2011
12.3 Cam and cylinder head removal / Reassembly
1. Turn the rotor to set the piston at top dead center of the compression stroke.
2. The timing mark of camshaft should be vertical to the cylinder head seal. Make sure the inlet and exhaust valve are closed.
3. Remove the timing chain tensioner.
4. Secure the timing chain with safety wire to prevent it from falling into the crank case.
5. Lift and remove the cam assembly from the head.
6. Carefully inspect the cam lobes, bearings and decompression operation.
● Cam height
Standard
29.026-29.086 mm (1.1431.145”)
Service limit
29.15 mm ( 1.104”)
Timing Chain
Tensioner
Cam Bearings
ON
Intake
Cam
Exhaust
Cam
Decompression
“ON”
OFF
Decompression
“OFF”
Decompression
Fly Weight
62 PH2100PRI SM 04-27-2011
7. While holding the safety wire that is attached to the timing chain, carefully remove the cylinder head and gasket.
Reassembly:
Timing
Chain
8. Replace the head gasket.
Head
Gasket
9. Follow the reverse procedure to reassemble.
Caution
Make sure that the piston is at top dead center which can also be confirmed by locating the crank shaft keyway in the vertical (Upright) position.
Install the chain onto the cam gear making sure that the timing mark is straight up before installing the rocker arm assembly.
Timing
Mark
Timing
Mark
Crankshaft
Keyway
63 PH2100PRI SM 04-27-2011
Reinstalling the timing chain tensioner:
10. Remove the adjustment cover screw and „O‟-ring.
11. Replace gasket.
12. Using a small flat blade screw driver rotate the spring loaded adjustment screw clockwise to retract the plunger.
13. Constant clockwise tension must be applied to the center screw until the tensioner is flush with the gasket before it is released.
Rotate tension
Screw
Clockwise to
Retract plunger
Normal
Position
Adjustment
Screw Cover and ‘O’-Ring
The Plunger must be kept in the retracted position while reinstalling.
64 PH2100PRI SM 04-27-2011
12.4 Inspection, valves and valve springs
● Free length of valve spring
Spring
Small
Large
Standard
35.5m
m (1.397”)
32.8mm (1.291”)
Service limit
31.1mm (1.224”)
33.8mm (1.330”)
● Valve seat width
Standard
1.0mm (0.039”)
Service limit
2.0mm (0.079”)
● Valve stem outer diameter
Intake valve
Exhaust valve
Standard
4.975 - 4.99mm (0.19580.1964”)
4.955 - 4.970mm (0.19500.1951”)
Service limit
4.92mm (0.1937”)
4.90mm (0.193”)
● Valve guide inner diameter
Inlet/Exhaust valve
Standard
5.000-5.030mm (0.1970.198”)
65
Service limit
5.060
mm (0.199”)
PH2100PRI SM 04-27-2011
12.5 Piston/Connection rod
Assembly of piston ring
Caution
● 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.
Manufacturers
Label
1 st
? ? ? ? ( ? ? ? )
2
ring nd
ring
活塞
Piston
活塞销卡环
Piston pin clip ring
组装：
Installation: set the front end in the piston groove, and clamp the other end. Install
住另一端， 边转动边安装到槽内。 the ring clip by revolving. Make sure that
不要使卡环的开口对着活塞销孔的缺 the gap of the ring clip is not in line with the groove in the piston pin hole.
连杆
卡环
Clip ring
。 aligned with the △ label on the piston.
66 PH2100PRI SM 04-27-2011
● Cylinder inner diameter
Standard
52.4000-52.420mm (2.0630-2.0638
”)
● Piston skirt outer diameter
Standard
52.360-52.380mm (2.061-2.06
2”)
Piston pin clip 10mm
Service limit
52.505mm (2.0671
”)
Service limit
52.25mm (2.05
7”)
● Side clearance of piston ring
1 st
and 2 nd
Ring
Oil Ring
Standard
0.02-0.06mm (0.0008-0.0024
”)
0.03-0.18mm (0.0010.007”)
Service limit
0.15
mm (0.0059”)
0.24
mm (0.009”)
67 PH2100PRI SM 04-27-2011
● Piston ring end clearance
Locate the piston ring into cylinder with piston top, and measure the piston end clearance.
1 st
and 2 nd
Ring
Oil Rings
Standard
0.15-0.25mm (0.00590.0098”)
0.20-0.50mm (0.00780.0196”)
Service limit
1.0
mm (0.039”)
1.0
mm (0.039”)
● Piston ring height
1 st
and 2 nd
Ring
Oil Rings
Standard
0.97-0.99mm (0.03810.0389”)
1.85-1.96mm (0.07280.0771”)
Service limit
0.87
mm (0.0342”)
1.75
mm (0.0688”)
68 PH2100PRI SM 04-27-2011
● Piston pin outer diameter
Standard
14.994-15.008mm (0.59030.5905”)
Service limit
14.95mm (0.5925”)
● Piston pin hole inner diameter
Standard
15.002-15.008mm (0.59070.5908”)
Service limit
15.05mm (0.5925”)
● Connection rod small end inner diameter
Standard
15.006-15.017mm (0.5900.5991”)
Service limit
15.08mm (0.594”)
69 PH2100PRI SM 04-27-2011
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Key Features
- Compact and portable for easy transport and storage
- CARB-certified for environmentally friendly operation
- Advanced parallel operation capability for increased power output
- User-friendly control panel and intuitive operation for ease of use
- Reliable power source for camping, tailgating, and emergencies
- Sturdy construction and durable components for longevity
- Quiet operation minimizes noise disturbance
Related manuals
Frequently Answers and Questions
What is the recommended maintenance schedule for the Powerhouse PH2100PRi?
How do I connect multiple Powerhouse PH2100PRi units for parallel operation?
What type of fuel does the Powerhouse PH2100PRi use?
How do I troubleshoot engine oil level issues?
What should I do if the engine speed is unstable or does not increase?
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