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Powerhouse Generator PH2400PRi

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PH2400 Digital Inverter GeneratorPi

SERVICE MANUAL

POWERHOUSE

2PH2400Pi SM, Rev. 2017-01-20

PREFACE

This manual covers the construction, function and servicing procedure of the POWERHOUSE

PH2400Pi generator, certificated by CARB.

Careful observance of these instructions will result in better, safer service work.

All information, illustrations, directions and specifications included in this publication are based on the

latest product information available at the time of approval for printing. Keystone Automotive Operations,

LLC reserves the right to make changes without incurring any obligation whatsoever. No part of this

publication may be reproduced without written permission.

Pay special attention to statements preceded by the following words:

 Indicates a strong possibility of severe personal injury or death if instructions are

not followed.

 Indicates a possibility of personal injury or equipment damage if instructions are

not followed.

 Gives helpful information.

 Please read and review the PH P2400 i Owner’s Manual before using this Service

Manual.

3PH2400Pi SM, Rev. 2017-01-20

CONTENTS

PREFACE ..................................................................................................................................................... 2

CONTENTS .................................................................................................................................................. 3

1. SPECIFICATIONS .................................................................................................................................... 6

1.1 Specications ............................................................................................................................................. 6

1.2 Characteristics ........................................................................................................................................... 7

1.3 Wiring Diagram .......................................................................................................................................... 8

2 SERVICE INFORMATION......................................................................................................................... 9

2.1 The Importance of Proper Servicing .......................................................................................................... 9

2.2 Important Safety Precautions 9....................................................................................................................

2.3 Servicing Rules ........................................................................................................................................ 10

2.4 Electrical Precautions .............................................................................................................................. 10

2.5 Serial Number Location ........................................................................................................................... 11

2.6 Engine Maintenance Standards ............................................................................................................... 12

2.7 Alternator Electrical Specications (Stator Windings) ............................................................................. 13

2.8 Torque Values .......................................................................................................................................... 13

3. MAINTENANCE ..................................................................................................................................... 14

3.1 Maintenance Schedule ............................................................................................................................ 14

3.2 Battery Maintenance ................................................................................................................................ 15

3.2.1 12V 5Ah AGM Starting Battery ........................................................................................................................ 15

3.2.2 3.6V Li ion Ignition Batteries- ............................................................................................................................ 16

3.3 Checking the Oil Level ............................................................................................................................. 17

3.4 Changing Oil ............................................................................................................................................ 18

3.5 Air Filter Inspection and Cleaning ............................................................................................................ 19

3.6 Spark Plug Inspection and Cleaning .......................................................................................................20

3.7 Valve Clearance Inspection and Adjustment ........................................................................................... 21

3.8 Evaporation Control ................................................................................................................................. 23

3.9 Fuel Filter Replacement ........................................................................................................................... 24

3.10 Spark Arrestor ........................................................................................................................................ 25

4. TROUBLESHOOTING ........................................................................................................................... 26

4.1 Starter Does Not Crank ........................................................................................................................... 27

4.2 Hard Starting ............................................................................................................................................ 28

4.2.1 Start Throttle Location Pre- ............................................................................................................................... 29

4.2.2 Primer Bulb Testing.......................................................................................................................................... 30

4.3 Cylinder Compression Check .................................................................................................................. 31

4.4 Ignition System ........................................................................................................................................ 32

4.4.1 Checking for Spark .......................................................................................................................................... 33

4.4.2 Ignition Coil / Trigger Assembly Inspection ...................................................................................................... 34

4.4.3 Ignition Switch Inspection ................................................................................................................................ 35

4.5 Oil Level Sensor Fails to Stop Engine with Low Oil ................................................................................. 36

4.5.1 Checking the Low Oil Sensor .......................................................................................................................... 37

4.6 Engine Stops Running ............................................................................................................................. 38

4.6.1 Fuel Pump Testing ........................................................................................................................................... 39

4.7 Engine Speed Cannot Increase or is Hunting ......................................................................................... 40

4.8 Engine Speed Too High ........................................................................................................................... 40