Power House PH3100RI Install guide

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POWERHOUSE® POWER PRODUCTS
PH3100Ri SHOP MANUAL
Coast Distribution System
August 2010
POWERHOUSE®

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PREFACE
This manual covers the construction, function and servicing procedure of the POWERHOUSE® PH3100Ri
generator, certificated by CARB.
Careful observance of these instructions will result in better, safer service work.
All information, illustrations, directions and specifications included in this publication are based on the latest
product information available at the time of approval for printing. Coast Distribution Systems, Inc. reserves
the right to make changes without incurring any obligation whatsoever. No part of this publication may be
reproduced without written permission.

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CONTENTS
1. SPECIFICATIONS
PREFACE..........................................................................................................................................................................2
CONTENTS ......................................................................................................................................................................3
1. SPECIFICATIONS........................................................................................................................................................6
1.1 SPECIFICATIONS..................................................................................................................................................6
1.2 CHARACTERISTICS.............................................................................................................................................7
1.3 Wiring Diagram w/o electric choke solenoid...........................................................................................................8
1.4 Wiring Diagram with electric choke solenoid, beginning with S/N 100602380706001 .........................................9
2. Service information .....................................................................................................................................................10
2.1 The importance of proper servicing.......................................................................................................................10
2.2 Important safety precautions..................................................................................................................................10
2.3 Service rules .......................................................................................................................................................... 11
2.4 Serial number location...........................................................................................................................................12
2.5 Engine maintenance standards...............................................................................................................................12
2.6 Motor.....................................................................................................................................................................14
2.7 Torque values.........................................................................................................................................................14
3. Trouble shooting.......................................................................................................................................................... 14
3.1 General symptoms and possible causes.................................................................................................................14
3.2 Hard starting.......................................................................................................................................................... 15
3.3 Cylinder compression check..................................................................................................................................16
3.4 Ignition system ...................................................................................................................................................... 17
3.5 Engine oil level is low, but engine does not stop................................................................................................... 19
3.6 Engine stops running (Throttle is in the correct position) .....................................................................................19
3.7 Engine speed can’t increase or is unstable (choke is in the correct position) ........................................................20
3.8 Engine speed too high or too low..........................................................................................................................20
3.9 Engine speed doesn’t increase with economy system “ON” and a load connected...............................................21
3.10 No or low AC output............................................................................................................................................21
3.11 Measuring stator output voltage while running ...................................................................................................22
3.12 No DC output at battery charge receptacle.......................................................................................................... 23
3.13 Battery will not charge.........................................................................................................................................23
3.14 No electric start....................................................................................................................................................25
2.15 Engine will not shut off with ignition key, remote or stop button .......................................................................26
3.16 Engine will not start or stop with remote............................................................................................................. 27
3.17 Engine will struggle when shut off with key or remote, but keeps running rough..............................................28
3.18 Engine will start and then shut down................................................................................................................... 29
4. Maintenance.................................................................................................................................................................30
4.1 Maintenance schedule............................................................................................................................................30
4.2 Checking the oil level............................................................................................................................................31
4.3 Changing oil ..........................................................................................................................................................32
4.4 Checking the low oil sensor...................................................................................................................................33
4.5 Air Cleaner............................................................................................................................................................. 34

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4.6 Spark plug..............................................................................................................................................................35
4.7 Valve clearance......................................................................................................................................................36
4.8 Evaporation Control System..................................................................................................................................36
5. Muffler system.............................................................................................................................................................38
5.1 Spark arrestor.........................................................................................................................................................38
5.2 Muffler................................................................................................................................................................... 39
6. Carburetor....................................................................................................................................................................40
6.1 Disassembly / Installation of Carburetor...............................................................................................................40
6.2 Disassembly / Installation of Step motor...............................................................................................................41
6.3 Step motor inspection............................................................................................................................................41
6.4 Fuel shutoff solenoid .............................................................................................................................................42
6.5 Backfire controller (BFP)6.6 Automatic choke assembly......................................................................................42
6.6 Automatic choke assembly.....................................................................................................................................43
6.7 High Altitude jet installation.................................................................................................................................. 44
7. Control panel ............................................................................................................................................................... 45
7.1 Disassembly / Installation......................................................................................................................................45
8. Outer generator housing ..............................................................................................................................................46
8.1 Disassembly / Installation......................................................................................................................................46
9. Recoil starter / Disassembly / Reassembly..................................................................................................................47
9.1 Inlet Fan Cover......................................................................................................................................................48
9.2 Starter motor.......................................................................................................................................................... 49
9.3 Start relay...............................................................................................................................................................50
9.4 Ignition coil Inspection..........................................................................................................................................51
9.5 Ignition coilAdjustment / Replacement ................................................................................................................ 52
10. Stator and Rotor disassembly / reassembly ............................................................................................................... 53
10.1 Stator Inspection..................................................................................................................................................53
10.2 Stator Removal/Reassembly................................................................................................................................ 54
11. Exploded engine view................................................................................................................................................55
12. Valve cover / Rocker arm...........................................................................................................................................58
12.1 Cylinder Head Removal ......................................................................................................................................58
12.2 Cylinder Head Disassembly and Reassembly...................................................................................................... 59
12.3 Inspection.............................................................................................................................................................60
13. Crankshaft / Piston.....................................................................................................................................................61
13.1 Crankshaft, camshaft and piston..........................................................................................................................61
13.2Alignment of timing marks.................................................................................................................................. 62
13.3 Camshaft Inspection ............................................................................................................................................63
13.4 Piston / Connection rod .......................................................................................................................................64

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1. SPECIFICATIONS
1.1 SPECIFICATIONS
Dimensions and weights
Model
PH3100Ri
Overall Length
24 in(610mm)
Overall Width
18 in (457mm)
Overall Height
18.3 in (464mm)
Net Weight
129 lbs (59 kg)
Engine
Model
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 15W-40 (SF/SG grade or greater)
Oil capacity
35 oz. (1.0 L)
Starting system
Remote, Electric, & Recoil
Stopping system
Primary circuit ground
Fuel used
Automotive unleaded gasoline
Alternator
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)

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1.2 CHARACTERISTICS
Model
PH3100Ri
Maximum output AC
3.1KW
Rated output AC
3.0KW
Rated output DC
100W
Rated frequency
60HZ
Rated voltage AC
120V
Rated voltage DC
12V
Rated current AC
25.0A
Rated current DC
8.3A
Power factor
1.0cosφ
Voltage variation rate Momentary
Average
Average time
10%max.
1.5%max.
3 sec. max.
Voltage stability
±1%
Frequency variation rate Momentary
Average
Average time
1%max.
1%max.
1 sec. max.
Frequency stability
±0.1%
Insulation resistance
10MΩmin.
AC circuit protector
20A and 30A (120V)
DC circuit protector
10A
Fuel tank capacity
4.4 gal (16.6L)
Continuous running time
(at rated load / at ¼ load)
7.6 hours / 17.8 hours
Noise level (Zero load to full load)
56-65 dB @ 23‟ (7m)

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1.3 Wiring Diagram w/o electric choke solenoid

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1.4 Wiring Diagram with electric choke solenoid, beginning with S/N 100602380706001
CHOKE

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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.) Be careful to avoid carbon monoxide poisoning from engine
exhaust.
b.) Make sure there is adequate ventilation whenever you run the
engine.
c.) Be careful to avoid burns from hot engine parts and hot exhaust.
d.) Let the engine cool before you touch it.
e.) Be careful to avoid injury from moving parts
■Do not run the engine unless the service manual instructs you to do so.
When the engine is running, keep your hands, fingers, and clothing away
from moving parts.
■To reduce the possibility of a fire or explosion, be careful when working
around gasoline. Use only a nonflammable solvent, not gasoline, to
clean parts. Keep all cigarettes, sparks, and flames away from fuel and all
fuel-related parts.

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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 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.
■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 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 an 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 contact with shape edges or corners, or
the end of any bolts or screws.
9. If a wire harness contacts the end of any bolts or screws or sharp edges or corners, protect that
part of the harness with a tube or by wrapping with an insulating tape. If the wire harness has a
grommet, install the grommet securely.
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. Before using the tester, carefully read the manufacturer‟s instructions and follow the instructions
in this Service Manual. Be sure that the test unit‟s battery is fully charged and verify that the unit
is operating correctly before you begin testing.

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Serial
Number
2.4 Serial number location
The generator‟s engine serial number identifies your particular unit and is required when ordering parts
and accessories. The generator serial number is also used by your dealer and Coast Distribution for
warranty administration and must be supplied before any work can be done.
The engine serial number can be found stamped on the engine block
above the oil dipstick. It is visible when the engine oil access cover is
removed.
2.5 Engine maintenance standards
Part
Item
Standard
Service limit
Engine
Maximum speed without load
3600±100rpm
—
Cylinder
Sleeve I.D.
77.000-77.020mm
(3.0315”-3.0323”)
77.105mm
(3.0356”)
Piston
Skirt O.D
76.960-76.980mm
(3.0299”-3.0307”)
76.85mm
(3.0256”)
Pin bore I.D.
18.002-18.008mm
(0.7087”-0.07090”)
18.05mm
(0.7106”)
Piston pin
O.D
17.994-17.000mm
(0.7084”-0.7087”)
17.95mm
(0.7067”)
Piston ring
1st ring
Height h
1.97-1.99mm
(0.0776”-0.0783”)
1.87mm
(0.0736”)
Ring side clearance
0.02-0.06mm
(0.001”-0.002”)
0.15mm
(0.006”)
Ring end clearance
0.15-0.25mm
(0.006”-0.010”)
1.0mm
(0.04”)
Width t
3.40-3.60mm
(0.134”-0.142”)
3.20mm
(0.126”)

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2.5 Engine maintenance standards, (continued)
Part
Item
Standard
Service limit
Piston ring
(continued)
2nd ring
Height h
1.97-1.99mm
(0.0776”-0.0783”)
1.87mm
(0.0736”)
Ring side clearance
0.02-0.06mm
(0.001”-0.002”)
0.15mm
(0.006”)
Ring end clearance
0.15-0.25mm
(0.006”-0.010”)
1.0mm
(0.04”)
Width t
3.40-3.60mm
(0.134”-0.142”)
3.20mm
(0.126”)
Oil ring
Height h
3.40-3.60mm
(0.134”-0.142”)
3.20mm
(0.126”)
Ring side clearance
0.03-0.18mm
(0.001”-0.007”)
0.24mm
(0.009”)
Ring end clearance
0.20-0.50mm
(0.008”-0.020”)
1.0mm
(0.04”)
Width t
2.3-2.7mm
(0.09”-0.11”)
2.2mm
(0.087”)
Connecting
rod
Small end I.D
18.006-18.017mm
(0.7089”-0.7093”)
18.08mm
(0.7118”)
Big end I.D
33.020-33.033mm
(1.3000”-1.3005”)
33.09mm
(1.303”)
Crankshaft
Crank pin O.D.
32.967-32.980mm
(1.2979”-1.2984”)
32.90mm
(1.295”)
Valves
Valve
clearance
IN
0.10±0.02mm
(0.004” ±.001”)
---
EX
0.15±0.02mm
(0.006” ±.001”)
---
Stem O.D.
IN
6.465-6.480mm
(0.2545”-0.2551”)
6.40mm
(0.2520”)
EX
6.455-6.470mm
(0.2541”-0.2547”)
6.40mm
(0.2520”)
Guide I.D.
IN/EX
6.500-6.530mm
(0.2559”-0.2571”)
6.56mm
(0.2583”)
Seat width
IN/EX
0.8mm (0.03”)
1.8mm (0.07”)
Valve spring
Free length
IN/EX
39.1mm (1.54”)
37.5mm (1.48”)
Cam wheel
Cam height
31.700-31.780mm
(1.2480”-1.2512”)
31.0mm
(1.2205”)
Carburetor
Main jet
0.8mm (.032”)
—
Float height
12
—
Pilot screw opening (Fixed)
N/A
—
Spark plug
Gap
0.6-0.7mm
(0.024”-0.028”)
—
Ignition coil
Resistance
Primary side
1.4-2.0 Ω
—
Second side
11.0-15.0kΩ
—

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2.6 Motor
Part
Item
Wire color
Standard(Ω)
DC winding
Resistance
blue－blue
0.045-0.070
Sub winding
Resistance
white－white
0.100-0.160
Main winding
Resistance
black－black－black
0.250-0.350
2.7 Torque values
Item
Specification
Tightening torque
Lbf-ft
N·m
Connection rod bolt
M8x40
21.4-23.6
29-32
Spark plug
M12x1x13
8.9-11.0
12-15
Crankcase cover
M8x35
20.7-22.9
28-31
Flywheel nut
M16x1.5
66.4-73.8
90-100
Standard torque
M5 Bolt, nut
4.4-5.9
6-8
M6 Blot, nut
5.9-7.4
8-10
M8 Bolt, nut
14.8-17.0
18-22
M10 Bolt, nut
40.6-44.3
55-60
Note: Use standard torque values for fasteners that are not listed in this table.
3. Trouble shooting
3.1 General symptoms and possible causes
Engine does
not start or
hard starting
Automatic choke
Inspect
Fuel filter clogged
Inspect / clean
Battery fuse
Inspect / replace
Fuel tank tube clogged
Inspect / clean
Fuel valve clogged
Inspect / clean
Fuel filter clogged
Inspect / replace
Carburetor faulty
Inspect / clean
Check valve / Choke pot faulty
Inspect / repair or replace
Ignition coil faulty
Inspect / replace
Spark plug faulty
Inspect / clean / replace
Spark plug cap loose
Tighten
Low oil sensor faulty
Inspect wiring / inspect sensor
Ignition module
Inspect
Ignition winding faulty
Inspect
Throttle not opening properly
Set in fully close or half close position
Engine speed
does not
stabilize, too
high or too low
Carburetor faulty
Inspect / disassemble and clean
Economy switch
Inspect
Throttle control motor (step motor)
faulty
Inspect wiring / inspect motor
Inverter unit faulty
Inspect / replace
Valve clearance misadjusted
Readjust

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3.2 Hard starting
Install a compression gauge in
the spark plug hole and check
the cylinder compression by
pulling the recoil starter rope
several times
1. Check the valve clearance
2. Check for carbon deposits in
the combustion chamber.
3. Check the valve cone and seat
4. Check for worn piston, piston
ring or cylinder.
Low cylinder
compression
Normal
compression
Install the spark plug securely.
Restart the engine according
to the starting procedure.
Install the spark plug and
ground the electrode. Check
the spark.
Perform the ignition system
troubleshooting
No spark or
weak spark
Good spark
Remove the spark plug and
check for wet or fouled
electrode.
Check fuel lines and carburetor for
any blockage or a stuck float.
Dry
Wet
Clean the electrode and restart,
taking care that the choke is not
closed too much. If flooding is
severe, check the carburetor float
valve.
Check the fuel level.
Add fuel and restart the engine.
No fuel
Sufficient fuel
Loosen the drain screw and
check whether fuel reached
the carburetor.
Check fuel filter and fuel valve.
Good spark
No fuel at
carburetor

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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. Push the remote switch to the OFF position.
4. Turn the ignition switch to the start position and measure the cylinder compression.
Cylinder compression
0.45Mpa (65 psi) /800rpm
Remote Switch
Pressure
Gauge

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3.4 Ignition system
Fill the oil reservoir to the correct level.
Use F7RTC 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 the spark plug into the plug cap.
3. Turn the ignition switch to the “ON”position. Attach the negative (—) electrode (i.e. threaded
part) of the spark plug to your ground wire and pull the recoil starter rope to check the spark
plug.
Ground
Wire
Spark Plug
Spark Plug
Boot
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”)
Perform the spark test again using a
new spark plug
Replace the spark plug
No spark
Good spark
No spark
Remove the control panel. Perform the
spark test using a new indicator
module.
Replace the module
Replace the ignition switch
Good spark
No spark
No spark
Check the ignition switch
Good spark
Replace the low oil alarm
Disconnect the low oil alarm and
perform spark test
Good spark
No spark
Abnormal
Check the resistance of stator ignition
winding
Replace the stator
Normal
Check the ignition coil resistance and
high pressure cable, high pressure
insulation cap.
Abnormal
Replace the ignition coil
Normal
Abnormal
Check the BFP controller
Replace the BFP controller
Normal
Abnormal
Check ignition coil air gap
Readjust air gap
Normal
Inspect or replace wire harness.

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3.5 Engine oil level is low, but engine does not stop.
3.6 Engine stops running (Throttle is in the correct position)
Sufficient fuel
Check the fuel valve and fuel filter for
blockage
Clear the fuel valve and
replace the fuel filter
Blocked
Not blocked
Check the fuel supply hose for blockage
Clear or replace the fuel
supply hose
Blocked
Not blocked
Add fuel and restart the engine
No fuel
Check fuel level
Check the oil level and oil sensor
Fill oil reservoir to the proper
level and restart the engine
Sufficient oil
Oil sensor
Check BFP controller
Replace
Abnormal
Normal
Normal
Perform the throttle control system test
Check the carburetor gasket for leakage
Tighten carburetor bolts or
replace gasket as required
Abnormal
Normal
Refer to step motor inspection
section in service manual
Abnormal
Normal
Check ignition coil
Readjust the coil clearance
Abnormal
Measure the cylinder compression
1. Check the valve clearance.
2. Check the carbon deposit in
combustion chamber.
3. Check the piston, piston ring
and cylinder for damage.
Abnormal
No continuity
No continuity
Continuity
Drain out oil completely, disconnect the oil
sensor wire harness, and check the
continuity between black wire and the
chassis ground. (Page 30)
Check and repair all wire
connections. Replace the
oil level alarm
Continuity
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 30)
Repair or replace the wire
harnesses
Indicator module fault, replace the module.

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3.7 Engine speed can’t increase or is unstable (choke is in the correct position)
3.8 Engine speed too high or too low
Check the AC output
Perform the generator trouble
shooting following the instruction
of “No or lowAC output”
Abnormal
Normal
Check the throttle control motor
Replace the throttle control motor
Abnormal
Normal
Check the Economy switch
Check Economy switch connection wire
Repair or replace the wire harness
Abnormal
Normal
Normal
Replace the Economy switch
Abnormal
Replace the inverter unit
Check the air filter element for blockage
Clear the air filter element
Not blocked
Blocked
Remove the spark plug and check the
electrode clearance for carbon deposit
Clear electrode, adjust
clearance or replace the spark
plug
Abnormal
Check the carburetor and nozzle for
blockage
Disassemble and clear.
Blocked
No blockage
Normal
Check the carburetor gasket for leakage
Tighten carburetor bolts or
replace gasket as required
Abnormal
Normal
Measure the cylinder compression
1. Check the valve clearance
2. Check the carbon deposit in
the combustion chamber
3. Check the piston, piston ring
and cylinder for damage
Abnormal
Normal
Perform the throttle control system test
Check the fuel filter for blockage
Replace fuel filter
Not blocked
Blocked
Inspect spark arrestor for carbon build up
Remove and clean carbon
deposits.
Blocked
Not blocked