Power House PH4000Ri/E User manual

PH4000Ri/E Digital Inverter Generator
SERVICE MANUAL
December 2014
POWERHOUSE ®

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PREFACE
This manual covers the construction, function and servicing procedure of the POWERHOUSE®PH4000Ri/E
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
PREFACE...........................................................................................................................................................2
CONTENTS........................................................................................................................................................3
1. SPECIFICATIONS..........................................................................................................................................6
1.1 SPECIFICATIONS....................................................................................................................................6
1.2 CHARACTERISTICS................................................................................................................................7
1.3 Wiring Diagram.........................................................................................................................................8
2. Service Information ........................................................................................................................................9
2.1 The Importance of Proper Servicing.........................................................................................................9
2.2 Important Safety Precautions...................................................................................................................9
2.3 Service Rules..........................................................................................................................................10
2.4 Electrical Precautions.............................................................................................................................10
2.5 Serial Number Location..........................................................................................................................11
2.6 Engine Maintenance Specifications.......................................................................................................11
2.7 Motor.......................................................................................................................................................13
2.8 Torque values .........................................................................................................................................13
3. Trouble Shooting..........................................................................................................................................13
3.1 Battery Charge Requirements................................................................................................................14
3.2 Starter Does Not Crank..........................................................................................................................14
3.3 Cranks But Doesn’t Start........................................................................................................................15
3.4 Hard Starting (cranks & starts, but is hard to start)................................................................................15
3.5 Cylinder Compression Check.................................................................................................................17
3.6 Ignition System.......................................................................................................................................18
3.6.1 Checking for Spark ..........................................................................................................................19
3.6.2 Ignition Coil Inspection.....................................................................................................................20
3.6.3 Ignition Switch Inspection................................................................................................................21
3.7 Oil level sensor fails to stop engine when oil is low...............................................................................22
3.8 Engine stops running..............................................................................................................................23
3.9 Engine speed can’t increase, is unstable or is hunting..........................................................................24
3.10 Engine speed too high..........................................................................................................................25
3.10.1 Engine Overspeed Protection........................................................................................................25
3.11 No or Low AC Output............................................................................................................................26
3.12 Measuring stator output voltage while running ....................................................................................27
3.13 No DC output at battery charge receptacle......................................................................................28
3.14 Battery will not charge..........................................................................................................................28
3.15 Engine will not start or stop with remote. .............................................................................................30
3.15.1 Remote Switch Inspection.............................................................................................................31
4. Maintenance.................................................................................................................................................32
4.1 Maintenance schedule............................................................................................................................32
4.2 Checking the oil level..............................................................................................................................33
4.3 Changing oil............................................................................................................................................33
4.4 Checking the Oil Level Sensor...............................................................................................................35

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4.5 Air Cleaner..............................................................................................................................................35
4.6 Spark plug...............................................................................................................................................37
4.7 Valve clearance......................................................................................................................................38
4.8 Evaporation Control System...................................................................................................................39
4.9 Fuel Filter................................................................................................................................................39
5. Muffler system..............................................................................................................................................40
5.1 Spark arrestor.........................................................................................................................................40
5.2 Muffler Removal......................................................................................................................................41
6. Electronic Fuel Injection (EFI)......................................................................................................................42
6.1 Overview of EFI System.........................................................................................................................42
6.2 Engine Control Unit (ECU) .....................................................................................................................43
6.3 Fault Codes..........................................................................................................................................44
6.3.1 Reading Fault Codes.......................................................................................................................44
6.3.2 Fault Code Definition and Descriptions...........................................................................................45
6.4 ManifoldAir Pressure Sensor (MAP)...................................................................................................46
6.4.1 MAP Voltage Output Test.................................................................................................................46
6.5 Oxygen Sensor (O2)...............................................................................................................................47
6.5.1 O2Sensor Output Test.....................................................................................................................47
6.5.2 Replacing the O2Sensor...............................................................................................................48
6.6 Temperature Sensor...............................................................................................................................49
6.6.1 Temperature Sensor Test.................................................................................................................49
6.7 Crankshaft Position Sensor (CPS).........................................................................................................50
6.7.1 Checking Coil Resistance ...........................................................................................................50
6.7.2Adjusting theAir Gap of the CPS.....................................................................................................50
6.8 Load Controller.......................................................................................................................................51
6.8.1 Fuel Pump Relay Test......................................................................................................................51
6.8.2 Overload Reset Button Test.............................................................................................................52
6.9 Fuel Injector.........................................................................................................................................53
6.9.1 Fuel Injector Test..............................................................................................................................53
6.10 Fuel Pump ............................................................................................................................................55
6.10.1 Testing the Fuel Pump...................................................................................................................55
6.10.2 Replacing and Servicing the Fuel Pump.......................................................................................56
6.11 Intake Manifold......................................................................................................................................57
6.11.1 Intake Manifold Removal ...............................................................................................................57
6.12 Throttle Control –Step Motor...............................................................................................................58
6.12.1 Removal and Installation of Step Motor ........................................................................................58
6.12.2 Resistance and Backlash of Step Motor .......................................................................................58
7. Control panel................................................................................................................................................59
7.1 Disassembly and installation..................................................................................................................59
7.2 Digital Display.........................................................................................................................................60
7.2.1 Voltage Display Field .......................................................................................................................60
7.2.2 Amperage and Wattage Display Fields ...........................................................................................61
7.2.3 Hour Meter.......................................................................................................................................61
7.2.4 Fuel Level Display............................................................................................................................62

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7.2.5 Low Oil Indicator Light.....................................................................................................................63
7.2.6 Fault Code Reset Button...............................................................................................................63
8. Outer Generator Housing.............................................................................................................................64
8.1 Disassembly and Installation..................................................................................................................64
9. Recoil Starter Disassembly and Reassembly..............................................................................................65
9.1 Intake Fan Cover....................................................................................................................................66
9.2 Starter motor...........................................................................................................................................67
9.2.1 Testing the Starter............................................................................................................................67
9.2.2 Removal and Replacement .............................................................................................................68
9.3 Starter relay............................................................................................................................................69
9.3.1 Testing Starter Relay on Generator.................................................................................................69
9.3.2 Bench Testing the Starter Relay......................................................................................................70
10. Stator and Rotor Disassembly and Reassembly.......................................................................................71
10.1 Stator Inspection...................................................................................................................................71
10.2 Stator Removal and Reassembly.........................................................................................................71
11. Exploded Engine View................................................................................................................................73
12. Cylinder Head / Valves...............................................................................................................................76
12.1 Cylinder Head Removal .......................................................................................................................76
12.2 Cylinder Head Disassembly and Reassembly.....................................................................................77
12.3 Inspection .............................................................................................................................................78
13. Crankshaft / Piston.....................................................................................................................................79
13.1 Crankshaft, Camshaft and Piston ........................................................................................................79
13.2 Alignment of Timing Marks...................................................................................................................80
13.3 Camshaft Inspection.............................................................................................................................81
13.4 Piston / Connecting rod........................................................................................................................82

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1. SPECIFICATIONS
1.1 SPECIFICATIONS
Dimensions and weights
Model
PH4000Ri/E
Overall Length
25.8 in (655mm)
Overall Width
23 in (584mm)
Overall Height
23.25 in (591mm)
Net Weight
146.8 lbs (66.6 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
Computer Controlled Electronic Ignition
Spark plug
F7RTC
Fuel System
EFI (Electronic Fuel Injection)
Air cleaner
Semi-dry type
Governor
Electronic control
Lubrication system
Splash
Lube oil
SAE 10W-30/15W-30 (SF/SG grade or greater) for temps above 32 F;
SAE 0W-30/0W-40 for temps below 32 F
Oil capacity
33.8 oz. (1.0 L)
Starting system
Remote, Electric, & Recoil
Stopping system
Electrical Fuel Cut-off
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 front of the generator)
Frequency regulation
AC-DC-AC conversion (Inverter type)
1.2 CHARACTERISTICS
Model
PH4000Ri/E
Maximum output AC
4.0KW
Rated output AC
3.6KW
Rated output DC
100W
Rated frequency
60HZ
Rated voltage AC
120V
Rated voltage DC
12V
Rated current AC
30.0A
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
10MΩ min.
AC circuit protector
20A and 30A (120V)
DC circuit protector
10A
Fuel tank capacity
4.5 gal (17.0 L)
Continuous running time
(at rated load / at ¼ load)
8.9 hours / 18.0 hours
Noise level (Zero load to full load)
64-73 dB @ 23’ (7m)

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1.3 Wiring Diagram

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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 Service 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 Service
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, make
sure there is adequate ventilation whenever you run the engine.
b.) Be careful to avoid burns from hot engine parts and hot exhaust, let the
engine cool before you touch it.
c.) 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.
2.4 Electrical Precautions
1. Hold the connector body to disconnect the connector. Do not disconnect by pulling the wire
harness. To disconnect the locking connector, be sure to unlock first, and then disconnect.
2. Check the connector terminals for bent pins, excessive stretching, missing terminals or other
abnormalities before connecting the connector.
3. To connect, insert the connector completely into the receptacle. If the connector is a locking type,
be sure that it is locked securely.
4. Check the connector cover for cracks or other damage and make sure the connector female
terminal fits snugly into the connector. Then, connect the connector securely. Check the
connector terminal for rust. Remove any rust using 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 sharp edges or corners or the
ends of any bolts or screws.
9. If a wire harness contacts the ends of any bolts or screws or sharp edges or corners, protect that
part of the harness 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
damaged insulation, repair by winding with the electrician’s insulating tape.
11. Before using test equipment, carefully read the manufacturer’s instructions and follow the
instructions in this Service Manual. Be sure that the test equipment battery is fully charged and
verify that the unit is operating correctly before you begin testing.

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Serial
Number
2.5 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.
2.6 Engine Maintenance Specifications
Part
Item
Specification
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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2.6 Engine Maintenance Specifications (continued)
Part
Item
Specification
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”)
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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2.7 Motor
Part
Item
Wire color
Specification(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
2.8 Torque values
Item
Specification
Tightening torque
Ft-lbs
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 Bolt, 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
Trouble Shooting Section Legend
3.1 Battery Charge Requirements
3.2 Starter does not crank
3.3 Cranks but does not start
3.4 Hard starting (cranks & starts, but is hard to start)
3.5 Cylinder compression check
3.6 Ignition system
3.7 Oil level sensor fails to stop engine when oil is low
3.8 Engine stops running
3.9 Engine speed can’t increase, is unstable or is hunting
3.10 Engine speed to high
3.11 No or low AC output
3.12 Measuring stator output voltage while running
3.13 No DC output at battery charge receptacle
3.14 Battery will not charge
3.15 Engine will not start or stop with remote, key operation normal

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3.1 Battery Charge Requirements
It is recommended that the battery be fully charged before starting any diagnostic work on the
generator.
This generator is equipped with an ECU, fuel pump and other EFI components that require 10.5VDC
minimum voltage to run properly. The battery must have a charge of at least 10.5VDC while being
cranked to be able to start the generator. If the battery has a charge in the range of 10-10.5VDC, the
generator may crank well, but the starter will be drawing most of the power and will cause a large
enough drop in voltage that the EFI system will not work properly. If the battery is at or near the
10.5VDC threshold it may still be possible to start the generator with the recoil starter, as this does
not cause a voltage drop during the starting process. However, this is why it is recommended the
battery be fully charged before doing any diagnostic work on the generator.
This generator comes equipped with 12V, 12Ah, AGM battery. This battery will be damaged by
improper charging or overcharging. Using a TC2-P plug-in trickle charger or equivalent is
recommended for charging this battery.
If the battery appears swollen or damaged, replace it. Do not replace this battery with one that has a
lower reserve capacity. It is recommended that the battery be replaced with the exact OEM
replacement battery.
3.2 Starter Does Not Crank
Normal
Abnormal
Abnormal
Normal
Normal
Abnormal
Normal
Abnormal
Abnormal
Charge battery using recommended
charger. Do a load test to make sure the
battery maintains adequate voltage under
load. Clean battery terminals. Replace
battery if necessary.
Make sure battery is in good condition
and fully charged. Refer to section 3.1.
Inspect the battery terminal connections.
Replace ignition switch and/or repair
wiring faults found.
Check the ignition switch. Refer to section
3.6.3.
Repair ground. Clean wire ends and
battery terminals. Remove paint, dirt, oil &
grease, or corrosion from chassis
grounds.
Check the ground between battery
negative terminal and the starter relay
body, the engine block, and control panel.
Replace the starter relay. See section 9.3.
Check the starter relay. See section 9.3.
If starter fails to operate properly replace
the starter motor. See section 9.2 for
details.
Inspect the starter motor wire and
connection. Test the starter motor. See
section 9.2.

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3.3 Cranks But Doesn’t Start
Normal
compression
Normal
Good spark
Normal
Good spark plug
Normal
Normal
No codes
Normal
Normal
Normal
Normal
Sufficient fuel
Normal
Abnormal
Low
cylinder
compression
Abnormal
No spark or
weak spark
Codes found
Worn or
fouled plug
Blown
Blocked
Faulty fuel
pump
Abnormal
Faulty fuel
injector
Faulty fuel
pump relay
No fuel
Low oil
Install the spark plug securely. Engine
should now start and run.
Perform compression test as detailed in
section 3.5.
1. Check the valve clearance (section 4.7).
2. Check for carbon deposits on the valves
& combustion chamber. Clean as
necessary.
3. Check the valve cone and seat (section
12). Lap valves, or replace & regrind as
necessary.
4. Check for worn piston, piston ring or
cylinder (section 13). Re-ring or
overhaul as necessary.
Replace Crankshaft Position Sensor or
repair as detailed in section 6.7.
Check for spark. See section 3.6.1.
Refer to ignition troubleshooting section
3.6. Perform necessary tests and repairs.
Check the fuel filter and fuel lines for
blockage. See section 4.9.
Replace fuel filter or lines. See section
4.9.
Remove and inspect the spark plug for a
worn, wet or fouled electrode. See
section 4.6 for details.
Clean or replace spark plug and perform
any service recommended in section 4.6
based on plug deposits.
Make sure battery is in good condition
and fully charged. Refer to section 3.1.
Inspect the battery terminal connections.
Charge battery using recommended
charger. Do a load test to make sure the
battery maintains adequate voltage under
load. Clean battery terminals. Replace
battery if necessary.
Check the 30Ain-line fuse located on the
battery power wire.
Replace fuse.
Check fault codes. See section 6.3.
Refer to section 6.3 for code descriptions.
Go to appropriate section for testing
based on code description.
Check fuel pump. See section 6.10.
Replace or repair fuel pump as required.
Inspect MAP sensor. See section 6.4.
Replace MAP sensor or repair as detailed
in section 6.4.
Check fuel pump relay (load controller).
See sections 6.8.1
Replace fuel pump relay (load controller).
Check fuel injector. See sections 6.9
Clean or replace fuel injector as required.
Add fuel and start the engine.
Check the fuel level.
Add oil and start the engine.
Check the oil level.
Inspect the Crankshaft Position Sensor.
See section 6.7.

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3.4 Hard Starting (cranks & starts, but is hard to start)
Low cylinder
compression
Normal
compression
Abnormal
Normal
No spark or
weak spark
Faulty fuel
Pump
Blocked
Normal
Good spark plug
Worn or
fouled plug
Abnormal
Normal
Sufficient fuel
No fuel
Low oil
Normal
Codes found
No codes
Good spark
Normal
Abnormal
Normal
Faulty fuel
pump relay
Normal
Normal
Faulty fuel
injector
Perform compression test as detailed in
section 3.5.
1. Check the valve clearance (section 4.7).
2. Check for carbon deposits on the valves
& combustion chamber. Clean as
necessary.
3. Check the valve cone and seat (section
12). Lap valves, or replace & regrind as
necessary.
4. Check for worn piston, piston ring or
cylinder (section 13). Re-ring or
overhaul as necessary.
Install the spark plug securely. Engine
should now start and run.
Inspect temperature sensor. See
section 6.6.
Replace temperature sensor or repair as
detailed in section 6.6.
Check for spark. See section 3.6.1.
Refer to ignition troubleshooting section
3.6. Perform necessary tests and repairs.
Check the fuel filter and fuel lines for
blockage. See section 4.9.
Replace fuel filter or lines. See section
4.9.
Remove and inspect the spark plug for a
worn, wet or fouled electrode. See
section 4.6 for details.
Clean or replace spark plug and perform
any service recommended in section 4.6
based on plug deposits.
Make sure battery is in good condition
and fully charged. Refer to section 3.1.
Inspect the battery terminal connections.
Charge battery using recommended
charger. Do a load test to make sure the
battery maintains adequate voltage under
load. Clean battery terminals. Replace
battery if necessary.
Check the fuel level.
Add fuel and start the engine.
Check the oil level.
Add oil and start the engine.
Check fault codes. See section 6.3.
Refer to section 6.3 for code descriptions.
Go to appropriate section for testing
based on code description.
Replace or repair fuel pump as required.
Check fuel pump. See section 6.10.
Inspect MAP sensor. See section 6.4
Replace MAP sensor or repair as detailed
in section 6.4.
Check fuel pump relay (load controller).
See sections 6.8.1
Replace fuel pump relay (load controller).
Check fuel injector. See sections 6.9
Clean or replace fuel injector as required.

17 PH4000Ri/E SM Revision 12-31-2014
3.5 Cylinder Compression Check
For safety, disconnect the 2-pin connector from the side of the fuel injector before
cranking the engine during the compression test. Take care when removing the
spring clip from this connector, as it is spring loaded and can fly off and be easily
lost.
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 hold until the compression gauge no longer
rises. Read compression.
Cylinder compression
0.45Mpa (65 psi) @ ~800rpm
Remote Switch
OFF
Compression
Gauge

18 PH4000Ri/E SM Revision 12-31-2014
3.6 Ignition System
This section deals with troubleshooting a faulty ignition system. Before diagnosing an ignition
problem, make sure the battery is fully charged and the terminal connections are clean and tight.
This generator is equipped with an EFI system that controls the ignition and requires 10.5VDC to run
properly. The battery must have a voltage of at least 10.5VDC while being cranked to be able to start
the generator. Thus it is recommended the battery be fully charged before doing any diagnostic work
on the generator. Consult section 3.1 for more details.
No spark
Good
spark
No spark
Blown fuse
Fuse good, no spark
Abnormal
No spark
No spark
Good
spark
Abnormal
No spark
Abnormal
Normal,
Still no spark
Abnormal
Normal,
Still no spark
Abnormal
Normal,
Still no spark
Still no
spark
Check for spark per section 3.6.1. Clean,
inspect and gap the plug per section 4.6.
Plug gap: 0.7-0.8mm (0.028”-0.031”).
Perform the spark test again using a new
spark plug.
Replace the faulty spark plug.
Test the ignition switch. See section 3.6.3.
Replace switch or repair as required.
Test the oil level sensor per procedure in
section 4.4. Replace or repair as
required.
Disconnect the oil level sensor and
perform spark test.
Replace ignition coil or repair as required.
Check the ignition coil, and spark plug
wire and cap resistance. See section
3.6.2.
Check the resistance of the Crankshaft
Position Sensor (CPS). See section 6.7.1.
Replace the Crankshaft Position Sensor
(CPS). See section 6.7.2.
Check the Crankshaft Position Sensor air
gap. See section 6.7.2.
Readjust the Crankshaft Position Sensor
air gap. See section 6.7.2.
Check the harness wires from the ignition
coil, CPS, ignition switch, and ECU for
breaks, shorts, or bad connections.
Repair or replace wire harness as
necessary.
Replace ECU. Spark should be restored.
Aproblem with the wire harness has been
overlooked. Repeat inspection of the wire
harness.
Check the 30Ain-line fuse located on the
battery power wire.
Replace fuse. Check spark.

19 PH4000Ri/E SM Revision 12-31-2014
3.6.1 Checking for Spark
Don’t pull the recoil starter or turn the ignition switch to “START” while touching
the high tension wire (spark plug wire).
1. Fill the oil reservoir to the correct operational level. Turn off
the remote switch for safety.
2. Pull off the spark plug cap and remove the spark plug
using a spark plug wrench.
3. Inspect the spark plug color and deposits (section 4.6).
Clean or replace plug, as necessary before checking
spark. Make sure you are using an F7RTC or equivalent
spark plug.
4. Remove clip and disconnect the power wires from the fuel
injector (Fig. 1). Use needle nose pliers when removing
the spring clip from this connector, as it is spring loaded
and can fly off and be easily lost. Pull the recoil starter
several times with the ignition switch OFF to clear
unburned gases from the cylinder.
5. Install the spark plug into the plug cap.
6. Attach a ground wire between the engine block and the
negative (-) electrode (the steel body of the spark plug) as
shown in Fig. 2.
7. Crank the engine over using the ignition key and
watch the spark plug gap for signs of spark. A healthy
ignition system will produce a spark as shown in Fig.
3.
8. If there is no, or a weak, spark; continue following the
ignition troubleshooting flowchart.
Fig. 1
Ground Wire
Fig. 3
Fig. 2

20 PH4000Ri/E SM Revision 12-31-2014
Fig. 4
2-Pin Coil
Connector
Check the primary
resistance between
these two wires.
Check the secondary
resistance between
these two wires.
3.6.2 Ignition Coil Inspection
Before beginning to test the ignition switch, make sure the battery is fully charged and the
terminal connections are clean and tight. See section 3.1 for battery charge requirements.
1. Remove the control panel and carefully let it hang out of the way. Locate the 2-pin primary
coil plug with a red wire with black stripe and blue wire with white stripe and unplug it from the
wiring harness (Fig. 4).
2. Attach the two leads of the tester to the red wire with black stripe and blue wire with white
stripe and measure the primary resistance of the ignition coil. The primary coil resistance
should be between 4.0-4.5Ω.
3. Check for continuity between the blue wire with white stripe, the red wire with black stripe, the
spark wire and either coil mount. There should be no continuity between any of these wires
and either coil mount.
4. If the primary coil resistance is outside the specified range, or there is continuity found
between any of the wires and either coil mount tested in step 3, replace the ignition coil.
5. To check the secondary resistance, attach one lead of the tester to the red wire with black
stripe of the primary plug of the ignition coil and the other lead to the spark plug cap. The
secondary coil resistance should be between 17.5-19.0Ω.
6. If the resistance is too high, remove the spark plug cap and check it again through the spark
plug wire itself. If the resistance is within range through the spark plug wire, but not the wire
and cap; replace the spark plug cap.
7. Replace the ignition coil if the resistance is outside of the range shown below.
Primary resistance
4.0-4.5Ω
Secondary resistance
17.5-19.0kΩ
There should be no continuity
between any coil wires and
the coil mounts.