Power House 2000Wi Install guide

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POWERHOUSE POWER PRODUCTS
2000Wi SHOP MANUAL
Coast Distribution
November, 2010
POWERHOUSE®

2 2000Wi SM 04-11-2012
Preface
This manual covers the construction, function and servicing procedure of the POWERHOUSE® 2000Wi
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. The 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.

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CONTENTS
Preface.........................................................................................................................................................2
CONTENTS..................................................................................................................................................3
1. SPECIFICATIONS....................................................................................................................................5
1.1 SPECIFICATIONS..............................................................................................................................5
1.2 CHARACTERISTICS..........................................................................................................................6
1.3 Wiring diagram, 2000Wi.....................................................................................................................7
2 Service Information...................................................................................................................................8
2.1 The importance of proper servicing....................................................................................................8
2.2 Important safety precautions..............................................................................................................8
2.3 Service rules.......................................................................................................................................9
2.4 Serial number location......................................................................................................................10
2.5 Engine maintenance standards........................................................................................................10
2.6 Motor.................................................................................................................................................11
2.7 Torque values ...................................................................................................................................12
3.Trouble shooting......................................................................................................................................13
3.1 General symptoms and possible causes .........................................................................................13
3.2 Hard starting.....................................................................................................................................14
3.3 Cylinder compression check ............................................................................................................15
3.4 Ignition system..................................................................................................................................16
3.5 Engine oil level is low, but engine does not stop..............................................................................18
3.6 Engine stops running (Throttle is in the correct position).................................................................18
3.7 Engine speed can’t increase or unstable (choke is at the correct position) ....................................19
3.8 Engine speed too high or too low.....................................................................................................19
3.9 Engine speed doesn’t increase with economy system “ON” and a load connected. ......................20
3.10 No or lowAC output........................................................................................................................20
3.11 Measuring stator output voltage while running...............................................................................21
3.12 No DC output at receptacle............................................................................................................22
3.13 Battery will not charge....................................................................................................................22
3.14 Voltage regulator ............................................................................................................................23
4. Maintenance schedule...........................................................................................................................24
4.1 Maintenance schedule......................................................................................................................24
4.2 Checking the oil level........................................................................................................................25
4.3 Changing oil......................................................................................................................................25
4.4 Checking for the low oil sensor ........................................................................................................26
4.5 Air Filter.............................................................................................................................................27
4.6 Spark plug.........................................................................................................................................28
4.7 Valve clearance ................................................................................................................................29
4.8 Fuel tank...........................................................................................................................................31
4.9 Evaporation Control..........................................................................................................................31
4.10 Fuel pump, primer bulb ..................................................................................................................32
5 Muffler system.........................................................................................................................................33
5.1 Spark arrestor...................................................................................................................................33
5.2 Muffler...............................................................................................................................................34
5.3 Exhaust tube, secondary air valve ...................................................................................................35

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6. Carburetor..............................................................................................................................................36
6.1 Disassembly/Installation of Carburetor ............................................................................................36
6.2 Disassembly/Installation of Step motor............................................................................................38
6.3 Disassembly/Installation of Carburetor ............................................................................................39
6.4 Stepping motor.................................................................................................................................40
7. Control panel..........................................................................................................................................41
7.1 Disassembly/Installation...................................................................................................................41
8. Outer generator housing........................................................................................................................43
8.1 Disassembly and installation of housing case .................................................................................43
9. Recoil starter / Ignition coil.....................................................................................................................44
9.1 Recoil starter/Disassembly/Reassembly..........................................................................................44
9.2 Ignition coil........................................................................................................................................45
9.3 Ignition coil / Disassembly................................................................................................................46
9.4 Adjustment........................................................................................................................................46
10. Rotor/Stator disassembly / reassembly...............................................................................................47
10.1 Disassembly/Reassembly..............................................................................................................47
10.2 Stator Inspection.............................................................................................................................48
11. Exploded engine view ..........................................................................................................................49
12. Valve cover/ Rocker arm......................................................................................................................52
12.1 Disassembly/ Reassembly.............................................................................................................52
12.2 Rocker Arm Inspection ...................................................................................................................53
12.3 Cam and cylinder head removal / Reassembly .............................................................................54
12.4 Inspection, valves and valve springs..............................................................................................57
12.5 Piston/Connection rod....................................................................................................................58

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1. SPECIFICATIONS
1.1 SPECIFICATIONS
Dimensions and weights
Model
2000Wi
Overall Length
21 1/4 in. (540mm)
Overall Width
11 1/4 in. (285mm)
Overall Height
19 1/8 in. (485mm)
Net Weight, with battery
62 lbs. (33kg)
Engine
Model
152F
Type
4-stroke,OVH, single cylinder, Gasoline engine
Displacement
125cc
Bore x stroke
52.4Χ57.8 mm
Maximum horsepower
4.35 Hp
Compression ratio
9.2:1
Cooling system
Forced air-cooled
Ignition system
Electronic
Spark plug
A7RTC
Carburetor
Float type, Horizontal, butterfly valve type
Air cleaner
Semi-dry type
Governor
Electronic control type
Lubrication system
Pump
Lube oil
SAE 15W-40 (SF/SG grade or greater)
Oil capacity
15.6 fl oz (0.460 L)
Starting system
Recoil starter
Stopping system
Primary circuit ground
Fuel used
Automotive unleaded gasoline

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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)
1.2 CHARACTERISTICS
Model
2000Wi
Maximum output AC
2.0 KVA
Rated output AC
1.9 KVA
Rated output DC
100W
Rated frequency
60HZ
Rated voltage AC
120V
Rated voltage DC
12V
Rated current AC
15.8A
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
DC circuit protector
10A
Fuel tank capacity
1.4 gal (5.3L)
Continuous running time at Rated load
~ 1/4 load
3.0 - 7.5 hours
Noise level (Zero load to full load)
56 - 63 dB (A)/7m

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1.3 Wiring diagram, 2000Wi

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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 for carbon monoxide poisoning from engine exhaust.
b.) Be sure there is adequate ventilation whenever you run the
engine.
c.) Be careful for burns from hot parts.
d.) Let the engine cool before you touch it.
e.) Be careful of injury from moving parts
Do not run the engine unless the instruction tells you to do so. Even
then, keep your hands, fingers, and clothing away.
To reduce the possibility of a fire or explosion, be sure 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.

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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 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.
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 fists 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 at 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 any shape edges or corners, or
the end of any bolts or screws.
9. If a wire harness contacts the end of the 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, set 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 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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2.4 Serial number location
The serial number can be found stamped on the engine block above oil dipstick. It is visible when the
maintenance panel is removed.
2.5 Engine maintenance standards
Part
Item
Standard(mm)
Service limit
Engine
Maximum speed without load
5000±100rpm
—
Cylinder
Sleeve I.D.
52.400-52.420mm
(2.0630”~2.0638”
52.505mm
(2.0671”)
Piston
Skirt O.D
52.360-52.380mm
(2.061”~2.062”)
52.25mm
(2.057”)
Pin bore I.D.
15.002-15.008mm
(0.5907”~0.5908
15.05mm
(0.5925”)
Piston pin
O.D
14.994-15.000mm
(0.5903”~0.5905”)
14.95mm
(0.588”)
Piston ring
1st ring
Height
0.97-0.99mm
(0.0381”~0.0389”)
0.87mm
(0.0342”)
Ring side clearance
0.02-0.06mm
(0.0008”~0.0024”)
0.15mm
(0.0059”)
Ring end clearance
0.15-0.25mm
(0.0059”~0.0098”)
1.0mm
(0.039”)
Width
1.90-2.10mm
(0.0748”~0.0826”)
1.80mm
(0.0590”)
2nd ring
Height
0.97-0.99mm
(0.0381”~0.0389”)
0.87mm
(0.0342”)
Ring side clearance
0.02-0.06mm
(0.0008”~0.0024”)
0.15mm
(0.0059”)
Ring end clearance
0.15-0.25mm
(0.0059”~0.0098”)
1.0mm
(0.039”)
Width
2.0-2.3mm
(0.0787”~0.0905”)
1.8mm
(0.0590”)
Oil ring
Height
1.85-1.96mm
(0.0728”~0.0771”)
1.75mm
(0.0688”)
Ring side clearance
0.03-0.18mm
(0.001”~0.007”)
0.24mm
(0.009”)
Ring end clearance
0.20-0.50mm
(0.0078”~0.0196”)
1.0mm
(0.039”)
Serial
Number

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Width
2.05-2.35mm
(0.0807”~0.0925”)
1.9mm
(0.0748”)
Part
Item
Standard(mm)
Service limit
Connecting rod
Small end I.D
15.006－15.017mm
(0.590”~0.591”)
15.08mm
(0.594”)
Valves
Valve clearance
IN
0.10±0.02mm
(0.0039” ± 0.0008”)
---
EX
0.15±0.02mm
(0.0059” ± 0.0008”)
---
Stem O.D.
IN
4.975-4.99mm
(0.1958”~0.1964”)
4.92mm
(0.1937”)
EX
4.955—4.970mm
(0.1950”~0.1951”)
4.90mm
(0.193”)
Guide I.D.
IN/EX
5.000—5.030mm
(0.197”~0.198”)
5.06mm
(0.199”)
Seat width
IN/EX
1.0mm
(0.039”)
2.0mm
(0.079”)
Valve spring
Free length
Outer spring
35.5mm
(1.397”)
33.8mm
(1.330”)
Inner spring
32.8mm
(1.291”)
31.1mm
(1.224”)
Cam wheel
Cam height
29.026-29.086mm
(1.143”~1.145”)
28.5mm
(1.104”)
Carburetor
Main jet
0.75mm
(0.030”)
—
Float height
12mm
(0.472”)
—
Pilot screw opening (Fixed)
N/A
—
Spark plug
Gap
0.6—0.7mm
(0.024”~0.028”)
—
Ignition coil
Resistance
Primary side
0.045-0.070Ω
—
Second side
5-8k Ω
—
2.6 Motor
Part
Item
Wire color
Standard(Ω)
120V
DC winding
Resistance
blue－blue
0.045~0.070 Ω
Sub winding
Resistance
white－white
0.100~0.160 Ω
Main winding
Resistance
black－black－black
0.250~0.350 Ω

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2.7 Torque values
Item
Specification
Tightening torque
Lbs-ft
N·m
Connection rod bolt
N/A
N/A
Spark plug
M10*1*13
9.6~11
13~15
Crankcase cover
M6*75
7.4-8.9
10-12
Flywheel nut
M12*1.25
51.8-59.2
70-80
Standard torque
M5 Bolt, nut
3.7~5.2
5-7
M6 Blot, nut
6~7.4
8-10
M8 Bolt, nut
13.3~16.2
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
hard starting
Fuel filter clogged
Replace
Fuel tank tube clogged
Inspect / clean
Fuel valve clogged
Inspect / clean
Carburetor faulty
Inspect / clean
Ignition coil faulty
Inspect / replace
Spark plug faulty
Inspect / clean / replace
Spark plug cap looses
Tighten
Low oil sensor faulty
Inspect wiring / inspect sensor
Ignition module
Inspect
Ignition winding faulty
Inspect
Throttle opening fault
Set in fully closed or half closed 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 engine switch in the OFF position.
4. Pull the starter rope quickly and measure the cylinder compression.
Cylinder compression
65 psi (0.45Mpa) 800rpm
Pressure
Gauge

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3.4 Ignition system
Fill the oil reservoir to the correct level.
Use A7RTC or equivalent spark plug.
Spark plug inspection
Don’t pull the recoil starter 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. Set the engine 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.
Spark Plug Wire
Spark Plug
Ground Wire

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Check the resistance of stator
ignition winding
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 sensor
Disconnect the low oil sensor and
perform spark test
Good spark
No spark
Abnormal
Replace the motor stator
Normal
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
Inspect or replace wire harness.
Abnormal
Normal
Check ignition coil air gap
Readjust air gap
Normal
Check the ignition coil resistance
and high pressure cable, high
pressure insulation cap.
Abnormal
Replace the ignition coil

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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)
Continuity
Drain out oil completely, disconnect the oil
sensor wire harness, and check the
continuity between black wire and the
chassis ground. (Page 26)
Check and repair all wire
connections. Replace the
oil level alarm
Continuity
No 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 26)
Repair or replace the wire
harnesses
No continuity
Indicator module fault, replace the module.
Check the fuel supply hose for blockage
Clear or replace the fuel
supply hose
Blocked
Not blocked
Not blocked
Check fuel level
Fill the tank with fuel and
restart the engine
No fuel
Sufficient fuel
Check the fuel valve and fuel filter for
blockage
Clear the fuel valve and
replace the fuel filter
Blocked
Check the oil level and oil sensor
Fill the oil reservoir to the
proper level and restart the
engine
Sufficient oil
Oil sensor
Perform the throttle control system test
Abnormal
Normal
Refer to step motor inspection
section in service manual
Check the carburetor gasket for leakage
Tighten carburetor bolts or
replace gasket as required
Abnormal
Normal
Check ignition coil
Readjust the coil clearance
Abnormal
Normal
Measure the cylinder compression
Abnormal
1. Check the valve clearance
2. Check the carbon deposit
in combustion chamber
3. Check the piston, piston ring
and cylinder for damage

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3.7 Engine speed can’t increase or unstable (choke is at the correct position)
3.8 Engine speed too high or too low
Remove the spark plug and check
the electrode clearance for carbon deposit
Clear electrode, adjust clearance
or replace the spark plug
Abnormal
Normal
Check the air filter element for blockage
Clear the air filter element
Not blocked
Blocked
Inspect spark arrestor for carbon build up
Remove and clean carbon
deposits.
Blocked
Not blocked
Check the carburetor and nozzle
for blockage
Disassemble and clear
Blocked
No blockage
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 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
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

20 2000Wi SM 04-11-2012
3.9 Engine speed doesn’t increase with economy system “ON” and a load
connected.
3.10 No or low AC output.
Check the AC output
Perform the generator
troubleshooting following the
instruction of “No or low AC output”
Abnormal
Normal
Check the step motor
Replace the step 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
Is the overload indicator light ON?
Disconnect the load, and restart
the engine
ON
OFF
Is the engine speed normal?
Economy switch
ON: 2300±100 rpm
OFF: 5000±100 rpm
Perform the throttle control
system test
Abnormal
Normal
Stop the engine and check the
AC receptacle
Replace the AC receptacle
Abnormal
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
1. Check and repair stator wire
harness or replace stator
2. Rotor inner magnetism
decreases, replace the rotor
Abnormal
Normal
Measure stator output with unit running
Replace stator
Abnormal