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Powerhouse Generator PH4000RiE

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PH4000Ri/E Digital Inverter Generator

SERVICE MANUAL

December 2014

POWERHOUSE

2 PH4000Ri/E SM Revision 12- -2014 31

PREFACE

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

® 00Ri PH40 /E

generator, certicated by CARB.

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

All information, illustrations, directions and specications 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.

3 PH4000Ri/E SM Revision 12- -2014 31

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 Specications ....................................................................................................... 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