POWERHOUSE. PH3300i Digital Inverter Generator SERVICE MANUAL

Transcription

1 POWERHOUSE PH3300i Digital Inverter Generator SERVICE MANUAL

2 PREFACE This manual covers the construction, function and servicing procedure of the POWERHOUSE PH3300i 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, Inc. 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 PH3300 Owner s Manual before using this Service Manual. 2 PH3300i SM, Rev

3 CONTENTS PREFACE... 2 CONTENTS GENERAL SPECIFICATIONS Specifications Characteristics Wiring Diagram SERVICE INFORMATION The Importance of Proper Servicing Important Safety Precautions Servicing Rules Electrical Precautions Engine Serial Number and Bar Code Number Engine Maintenance Specifications Alternator Electrical Specifications (Stator/Rotor Windings) Torque Values MAINTENANCE Maintenance Schedule Battery Maintenance V 10Ah AGM Starting Battery V Li-ion Ignition Batteries Checking the Oil Level Changing Oil Air Filter Inspection and Cleaning Spark Plug Inspection and Cleaning Valve Clearance Inspection and Adjustment Evaporation Control System Replacing Fuel Filter Spark Arrestor TROUBLESHOOTING Starter Does Not Crank Hard Starting Pre-Start Throttle Location Cylinder Compression Check Ignition System Checking for Spark Ignition Coil/Trigger Assembly Inspection Ignition Switch Inspection Oil Level Sensor Fails to Stop Engine with Low Oil Checking the Low Oil Sensor Engine Stops Running PH3300i SM, Rev

4 4.6.1 Fuel Pump Testing Engine Speed Cannot Increase or is Hunting Engine Speed Too High No or Low AC Output Measuring Stator Main Output Voltage While Running No DC Output At Battery Charge Receptacle Starting Battery Will Not Charge Voltage Regulator Testing Engine Runs-on or Backfires After Being Turned Off Engine Will Start Then Shut Down REPAIR Carburetor Removal / Installation of Carburetor Throttle Control Step Motor Backfire Prevention Solenoid (BFP) Manual Choke Assembly High Altitude Jet Control Panel Disassembly / Installation Outer Generator Housing Disassembly / Installation Recoil Starter Disassembly / Reassembly Starter motor Starter Testing Starter Removal / Replacement Starter Relay Testing Starter Relay on Generator Bench Testing the Starter Relay Intake Fan Cover Ignition Coil/Trigger Assembly Adjustment / Replacement Stator and Rotor Stator Inspection Stator Removal and Reassembly Inverter Inspection / Adjustment / Replacement Inverter Removal / Preparation for Adjustment Inverter Adjustment / Replacement Inverter Ignition Power Muffler Removal / Replacement Engine Exploded View Cylinder Head / Valves Cylinder Head Removal Cylinder Head Disassembly and Reassembly PH3300i SM, Rev

5 Valve and Spring Inspection Crankshaft / Camshaft / Piston Disassembly and Reassembly Alignment of Timing Marks Camshaft Inspection Piston / Connecting Rod PH3300i SM, Rev

6 1. GENERAL SPECIFICATIONS 1.1 Specifications Dimensions And Weights Model PH3300i Overall Length 603mm (23.75 ) Overall Width 476mm (18.75 ) Overall Height 546mm (21.25 ) Net Weight 61 kg (134 lbs.) Engine Model XG-177F Type 4-stroke,OHV, single cylinder, Gasoline engine Displacement 270cc Bore x stroke 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 10W-30 (SF/SG grade ) above 0 C (32 F); SAE 0W-30/0W-40 below 0 C (32 F) Oil capacity 1.0 L (35 oz.) Starting system Electric & Recoil Stopping system Primary circuit ground Fuel used Automotive unleaded gasoline Alternator Alternator type Alternator structure Excitation Phase Rotating direction Frequency regulation Multi pole rotation type Self-ventilation drip-proof type Self-excitation (Magnet type) Single phase Clockwise (Viewed from the generator) AC-DC-AC conversion (Inverter type) 6 PH3300i SM, Rev

7 1.2 Characteristics Model PH3300 Maximum output AC 3300W Rated output AC 3200W Rated frequency 60HZ Rated voltage AC 120V Rated voltage DC 12V Rated current AC 26.7A 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 16.3L (4.3 gal) Continuous running time (at rated load ½ at ¼ load) 10.9 hours / 16.6 hours Noise level (Zero load to full load) m (23 ) 7 PH3300i SM, Rev

8 1.3 Wiring Diagram 8 PH3300i SM, Rev

9 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 and 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 of every conceivable hazard that can arise in performing servicing 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 injured 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. Wear appropriate clothing and personal protective equipment. When performing servicing or repairs, the below CAUTION steps must be followed: Read the instructions before you begin any servicing, be sure you have the equipment and skills required to perform the tasks safely. Be sure that the engine is off before you begin any servicing or repairs. To avoid carbon monoxide poisoning from engine exhaust, make sure there is adequate ventilation whenever you run the engine. To avoid burns from hot engine parts and hot exhaust, let the engine and exhaust cool before touching them. To avoid injury, use caution when working around 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 cautious when working around gasoline. Use only a nonflammable solvent and not gasoline to clean parts. Keep all cigarettes, sparks and flames away from fuel and all fuel-related parts. 9 PH3300i SM, Rev

10 2.3 Servicing 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 a fine 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 come in 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 by wrapping insulating tape on the sharp surface. 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. 10 PH3300i SM, Rev

11 2.5 Engine Serial Number and Bar Code Number The generator bar code number (BCN) and the engine serial number (ESN) identify your particular unit and are necessary when ordering parts and accessories. These two numbers are used by your dealer and Keystone Automotive Operations for warranty administration and must be supplied before any work can be done. The BCN is found in three locations: 1. On the side of the generator, lower left of the oil access door. 2. On the back of the Owner s Manual. 3. On the outside of the shipping carton. 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 (Fig. 1). Fig Engine Maintenance Specifications Part Item Specification Service limit Engine Maximum speed without load 3600±100rpm Cylinder Piston Piston pin Piston ring 1st ring Sleeve I.D. Skirt O.D. Pin bore I.D. O.D. Height Ring side clearance Ring end clearance Width mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) 76.85mm ( ) 18.05mm ( ) 17.95mm ( ) 1.87mm ( ) 0.15mm (0.006 ) 1.0mm (0.040 ) 3.2mm (0.126 ) 11 PH3300i SM, Rev

12 2.5 Engine Maintenance Specifications (continued) Part Item Specification Service limit Piston ring (continued) Connecting rod Crankshaft Valves 2nd ring Oil ring Valve clearance Stem O.D. Guide I.D. Height Ring side clearance Ring end clearance Width Height Ring side clearance Ring end clearance Small end I.D. Big end I.D. Crank pin O.D. Width IN EX IN EX IN/EX mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) mm ( ) 0.10±0.02mm (0.004 ±.001 ) 0.15±0.02mm (0.006 ±.001 ) mm ( ) mm ( ) mm ( ) 1.87mm ( ) 0.15mm (0.006 ) 1.0mm (0.040 ) 3.20mm (0.126 ) 3.20mm (0.126 ) 0.24mm (0.009 ) 1.0mm (0.040 ) 2.2mm (0.087 ) 18.08mm (0.712 ) 33.09mm (1.303 ) 32.90mm (1.295 ) mm ( ) 6.40mm ( ) 6.56mm ( ) 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 Lobe Cam Lobe height mm ( ) 31.00mm ( ) Main jet 0.79mm (.0310 ) Carburetor Float height 12 Pilot screw opening (Fixed) N/A Spark plug Gap mm ( ) Ignition coil Resistance Primary side Ω Second side kΩ Trigger coil Resistance Ω 12 PH3300i SM, Rev

13 2.7 Alternator Electrical Specifications (Stator/Rotor Windings) Part Item Wire color Specification(Ω) DC winding Resistance blue-blue Sub winding Resistance white-white Main winding Resistance black-black-black Torque Values Item Specification Tightening torque ft-lb N m Connection rod bolt M8x Spark plug M12x1x Crankcase cover M8x Flywheel nut M16x M5 Bolt, nut Standard torque M6 Bolt, nut M8 Bolt, nut M10 Bolt, nut Use standard torque values for fasteners that are not listed in this table. 13 PH3300i SM, Rev

14 3. MAINTENANCE 3.1 Maintenance Schedule Item Maintenance Procedure Regular Service period. Perform at every indicated month or operating hour interval, whichever occurs first. 1 st Month Every 3 Every 6 1x per Year Each Use or 4 to 6 Months or Months or or 300 HRS Hours 50 HRS 100 HRS Engine Oil Check O Change O O Check O Air cleaner Clean O(2) Spark Plug Clean - adjust O Spark Arrester Clean O Fuel Filter Check Replace O O(2) Valve clearance Check - Adjust O(3) Fuel tank & strainer Clean O(2) Fuel line Check Every 2-years (Replace as necessary) 12V 10Ah AGM Starting Battery 3.6V Li-ion Ignition Batteries Clean - Charge Inspect - Replace Charge monthly during long term storage. Check terminals for corrosion monthly, clean as needed. Expected battery life is 2 years, but can be affected by operating environment. Check the voltage and inspect the terminals monthly during long term storage. The voltage should be V depending on the temperature. If the voltage is low, or the terminals are corroded, replace the Li-ion batteries. Expected battery life is 2 years, but can be affected by operating environment. Notes: (1) Log Hours of operation to determine proper maintenance (2) Service more frequently when used in dusty areas. (3) These items should be serviced by an authorized dealer unless the owner has the proper tools and is mechanically proficient. 14 PH3300i SM, Rev

15 3.2 Battery Maintenance It is recommended that the starting battery and ignition batteries be fully charged before starting any diagnostic work on the generator V 10Ah AGM Starting Battery This generator comes equipped with 12V, 10Ah, AGM starting battery located behind the maintenance door. This battery is charged by the generator during periods of frequent usage; if the battery is not holding a charge refer to (section 4.12). During periods of infrequent use it is recommended that the battery be charged monthly. A TC2-P plug-in trickle battery charger or equivalent is recommended. The battery will be damaged by improper charging or overcharging. If this battery appears swollen or damaged, replace it. Do not replace this battery with one that has less than 10Ah capacity. It is recommended that the battery be replaced with the exact OEM replacement battery V Li-ion Ignition Batteries This generator comes equipped with two Panasonic NCR18650B 3.6V Li-ion ignition batteries which have a 3350mAh capacity and protective circuitry (Fig. 2). They are located in a tray, mounted on the air cleaner cover. They can be accessed by removing the control panel and carefully letting it hang from its connections (Fig. 3). These batteries provide power for pre-start throttle location, and auxiliary ignition power. They are charged while the generator is running. Inspect them periodically, or as part of a troubleshooting procedure. Remove the batteries from their tray for inspection; their voltage should be V depending on the temperature. If the voltage is 2.7V, replace both of the Li-ion batteries. If the Li-ion batteries are not maintaining their charge during frequent generator usage, then check the charging voltage between the red and black wires of the Li-ion battery connector (Fig. 3) while the generator is running. The charging voltage can be checked with the batteries in, or out, of the tray. It should be V. If the voltage is within this range but the batteries are not maintaining their charge, replace the batteries. If the charging voltage is not in this range then test the voltage regulator refer to (section 4.13). Check the Li-ion batteries voltage and inspect the terminals monthly during long term storage. If the voltage 2.7V or the terminals are corroded, replace the Li-ion batteries. This battery must be replaced with the OEM replacement battery or the exact equivalent (this battery is typically listed as 3.7V and 3400mAh by most retailers). Fig. 2 Fig. 3 Put the positive end of both of the Li-ion batteries towards the top of the tray. Li-ion Battery Connector 15 PH3300i SM, Rev

16 3.3 Checking the Oil Level Stop the engine and check the oil level, be sure to put the engine on a flat surface when checking. 1. Loosen the screw on the engine oil access cover and remove the cover. 2. Remove the oil filler cap and check for the oil level. 3. If the oil level is low, add oil until it reaches the edge of the upper line on the dipstick (when screwed in as shown in Fig. 4). 4. Re-install the dipstick and the engine oil access door before restarting your generator. Fig. 4 Upper Limit Lower Limit Upper level Lower level 16 PH3300i SM, Rev

17 3.4 Changing Oil Make sure to turn the engine switch and fuel lever OFF before draining. Drain the oil while the engine is still warm to assure rapid and complete draining. 1. Loosen the screw on the engine oil access cover and remove the cover. 2. Remove the oil filler cap. 3. Install the oil drain pipe. 4. Drain dirty oil into a container. Allow enough time for the oil to drain completely. 5. Refill with the recommended oil, and check the oil level. 6. Reinstall the access cover and tighten the screw securely. Fig. 5 Engine oil capacity: 1.0L (35 oz.) Upper Limit Upper level Lower Limit Lower level Please dispose of used motor oil in a manner that is compatible with the environment and local disposal regulations. Do not throw oil in the trash or pour oil on the ground. 17 PH3300i SM, Rev

18 3.5 Air Filter Inspection and Cleaning 1. Loosen the panel screws and remove the side maintenance door. 2. Remove the two filter cartridge retaining screws. 3. Remove the filter cartridge and the filter element. 4. If filter element and the filter case are soaked with excessive engine oil this could be a sign of excessive blow-by or a defective PCV valve. Pull the spark plug to check for signs of oil burning or fouling (section 3.6). If the plug looks normal but the PCV hose is full of oil, replace the PCV valve (must replace the whole valve cover). 5. Wash the filter element in a non-flammable or high flash point solvent and dry them thoroughly. 6. Soak the filter element in clean engine oil and squeeze out any excess oil. 7. Reinstall the filter element and the air filter cartridge. Tighten the two cartridge screws securely. 8. Reinstall the maintenance door and tighten the screws securely. Fig. 6 Air Filter Cartridge Air Filter Element Air Filter Case Maintenance Door A dirty air filter will restrict air flow to the engine, reducing engine performance. If the engine is operated in dusty areas, clean the air filter more often than specified in the Maintenance Schedule (section 3.1). Never run the engine if there is no filter element or if the filter is damaged, as it will cause serious damage to the engine. 18 PH3300i SM, Rev

19 3.6 Spark Plug Inspection and Cleaning 1. Remove the spark plug using a plug wrench and carefully inspect it. Compare the color and deposits on the plug to Fig. 7. It should look normal, or worn if it is time for replacement. Evidence of lean, rich or flooded conditions indicate there is a carburetor, choke, or fuel delivery issue. Ash deposits are evidence of oil burning under normal combustion conditions and usually show up toward the end of the engine s service life; more frequent plug replacement will be required. Oil fouling is evidence of far too much oil entering the cylinder, usually engine repair will be required to fix the problem (sections 5.12, 5.13 & 5.14). Oil burning can also be caused by a faulty PCV valve (built into the valve cover). This will cause large amounts of engine oil to get pulled through the PCV hose, collect in the air cleaner, and get sucked into the carburetor. If this is the case, try replacing the PCV valve (valve cover). NEW Carbon Too Rich NORMAL WORN LEAN FLOODED Ash deposits - Burning oil Oil Fouled Fig Remove carbon or other deposits with a plug cleaner or stiff wire brush. Check the sealing washer for damage. Spark Plug Type F7RTC 3. Measure the plug resistance; replace the spark Spark Plug Resistance 3-9 kω plug if the resistance is outside of these values. 4. Measure the plug gap with a wire-type feeler gauge. Adjust by bending the side electrode if the measurement is not within the specified tolerance mm Spark Plug Gap mm ( ) 5. Install the plug finger tight to seat the washer and then tighten with a plug wrench. Torque the spark plug to 11-13Nm (8-10ft-lbs) or ⅛ of a turn after seating with a previously compressed washer, or ¼ turn after seating with a new uncompressed washer. Torque valve is ft.-lbs. (11-13 Nm) 19 PH3300i SM, Rev

20 3.7 Valve Clearance Inspection and Adjustment Valve clearance inspection and adjustment must be performed with the engine cold. 1. Remove spark plug, valve cover bolt, valve cover and valve cover gasket. Spark Plug Fig. 8 Valve Cover Gasket Valve Cover Valve Cover Bolt 2. Rotate the engine in a clockwise direction until the piston is at top dead center (TDC) and the intake and exhaust valves are closed. 3. Insert a feeler gauge between the rocker arm and the valve and measure the valve clearance, see Fig. 9. Valve clearance Intake 0.10 ± 0.02mm (0.004 ±0.001 ) Exhaust 0.15 ± 0.02mm (0.006 ±0.001 ) 4. If adjustment is necessary, proceed as follows: a. Secure the rocker arm adjustment nut and loosen the jam nut. b. Adjust the rocker arm nut until the desired valve clearance is attained. c. Secure the rocker arm nut and tighten the jam nut. Recheck the clearance. 5. Clean the cylinder block and valve cover. 6. Replace the rubber valve cover seal. 7. Install the removed parts in the reverse order of removal. Fig PH3300i SM, Rev

21 3.8 Evaporation Control System The evaporative control system is shown below (Fig. 10). The 380cc carbon canister must be present and connected as shown to meet CARB evaporative emission standards. Use the OEM replacement hose, if possible. This grade of hose is commonly available at auto part stores as fuel hose, if the OEM replacement hose is unavailable. Fig. 10 Vent Hose from Air Filter Fuel Tank Vent Hose from Tank 380cc Carbon Canister Air Filter case 21 PH3300i SM, Rev

22 3.9 Replacing Fuel Filter Use only the OEM Powerhouse replacement fuel filter when servicing this generator. Take care not to introduce any debris or contaminants in the fuel system during this process. Contaminants introduced here will likely end up in the carburetor. 1. Remove the 6 control panel screws and carefully allow the control panel to hang out of the way. 2. Remove hose clamps and remove fuel filter (Fig. 11 and Fig. 12). 3. Reassemble in reverse order. Fig. 12 Fig PH3300i SM, Rev

23 3.10 Spark Arrestor If the generator has been running, the muffler will be very hot. Allow the muffler to cool before proceeding. The spark arrester must be serviced every 100 hours to maintain efficiency. A clogged spark arrestor will partially plug the exhaust system causing a substantial loss in power and performance. 1. Remove the exhaust grill to access the spark arrestor (Fig. 13). 2. Remove the clamp holding the spark arrester to the muffler. 3. Remove the spark arrester. 4. Clean the spark arrestor with a wire or nylon brush and compressed air. 5. Replace the spark arrestor if the wire mesh is perforated or torn. 6. Reinstall the spark arrester. 7. Reinstall the clamp holding the spark arrester to the muffler. 8. Reinstall the exhaust grill. Fig. 13 Spark Arrestor Clamp Exhaust Grill 23 PH3300i SM, Rev

24 4. TROUBLESHOOTING Trouble Shooting Section Legend 4.1 Starter Does Not Crank 4.2 Hard Starting 4.3 Cylinder Compression Check 4.4 Ignition System 4.5 Oil Level Sensor Fails to Stop Engine with Low Oil 4.6 Engine Stops Running 4.7 Engine Speed Can t Increase or is Hunting 4.8 Engine Speed Too High 4.9 No or Low AC Output 4.10 Measuring Stator Main Output Voltage While Running 4.11 No DC Output at Battery Charge Receptacle 4.12 Starting Battery Will Not Charge 4.13 Voltage Regulator Testing 4.14 Engine Runs-on or Backfires After Being Turned Off 4.15 Engine Will Start Then Shuts Down 24 PH3300i SM, Rev

25 4.1 Starter Does Not Crank Make sure the starting battery is in good condition and fully charged (section 3.2.1). Inspect the battery terminal connections. Normal Check the ignition switch (section 4.4.3). Normal Check the ground between the battery negative terminal and the starter relay body, the engine block, and control panel. Normal Check the starter relay (section 5.6). Normal Abnormal Abnormal Abnormal Abnormal Charge the battery using recommended charger. Do a load test to make sure the battery maintains adequate voltage under load. Clean battery terminals. Replace the battery if necessary. Replace ignition switch and/or repair wiring faults found. Repair ground. Clean wire ends and battery terminals. Remove paint, dirt, oil & grease, or corrosion from chassis grounds. Replace the starter relay (section 5.6). Inspect the starter motor wire and connection. Test the starter motor (section 5.5). Abnormal If starter fails to operate properly replace the starter motor (section 5.5). 25 PH3300i SM, Rev

26 4.2 Hard Starting Make sure the starting and Li-ion batteries are in good condition and fully charged (section 3.2). Inspect the battery terminal connections. Normal Check the fuel level in fuel tank. Sufficient fuel Loosen the carburetor drain screw to verify if fuel has reached the carburetor (section 5.3.1, Fig. 30). Fuel present Verify manual choke is in the correct position and operating properly. Choke OK Check the oil level. The low oil sensor can cause hard starting if the oil is at, or near, the critically low level. Oil level good Remove and inspect the spark plug for a worn, wet or fouled electrode (section 3.6). Good spark plug Check for spark (section 4.4.1). Normal Perform compression test (section 4.3). Normal compression Install the spark plug securely. Engine should now start and run. Abnormal Low fuel No fuel Choke needs adjustment Low oil Worn or fouled plug No spark or weak spark Low cylinder compression Charge the starting battery using a recommended charger. Do a load test to make sure the starting battery maintains adequate voltage under load. Clean battery terminals (section 3.2). Replace any batteries if necessary. Add fuel and start the engine. If starting with a dry fuel system, use 1.5 gallons. Check the fuel filter (section 3.9), fuel pump (section 4.6.1), fuel valve, fuel lines and carburetor for blockage, water in fuel, and/or a stuck float. Clean or repair as necessary. Use FULL choke for cold engine and during cold weather, use ½ choke for cold engine and air temp 50 F, use no choke on a hot engine. Verify proper choke operation (section 5.1.4). Add oil (section 3.3) and start the engine. Clean or replace spark plug and perform any service recommended in (section 3.6) based on plug deposits. Refer to ignition troubleshooting (section 4.4). Perform tests and repairs. 1. Check the valve clearance (section 3.7). 2. Check head gasket. 3. Check for carbon deposits on the valves & combustion chamber. Clean as necessary. 4. Check the valve cone and seat (section ). Lap valves, or replace & regrind as necessary. 5. Check for worn piston, piston ring or cylinder (section ). Re-ring or overhaul as necessary. 26 PH3300i SM, Rev

27 4.2.1 Pre-Start Throttle Location During normal generator shutdown, the inverter sees the 120V output voltage fall to 0V as the engine dies after the ignition key is turned off. The inverter s programmed response is to open the carburetor throttle to demand more power from the engine in an effort to maintain 120V output. This could leave the throttle wide open after shutdown, and this is not the optimal position for starting the engine later; especially in cold weather. Therefore, this generator has a pre-start throttle location sequence programmed into the inverter to locate the throttle and position it in an optimal position. This occurs immediately after the ignition key is turned to the ON position but before the starter cranks or the recoil starter is pulled. It does this by first closing the throttle all the way (to a known position), and then opening it approximately 20%. This operation only takes a fraction of a second. It does it when the key is first turned to the ON position, and again between every subsequent starting attempt (if the engine does not start). This feature is powered by the Li-ion ignition batteries. If this feature is not working it can make the generator more difficult to start. A procedure for checking this function is shown below. Note that once the ignition has been turned to the ON position and throttle has been located, the inverter will remember it is in the correct position for one minute. Turning the ignition OFF and ON again during this period will not induce another throttle location process. If the ignition has been turned ON prior to beginning this test, wait at least one minute before conducting the test below. 1. Remove the maintenance door. 2. Look in the area circled in red in (Fig. 14) to acquire a clear view of the throttle plate/step motor linkage. Use a flashlight if necessary. 3. Turn the ignition key to the ON position while maintaining a view on the throttle plate/step motor linkage. It should go through the pre-start throttle location process immediately when the key is turned ON. Maintain a careful watch on this area while turning the key, the process takes only a fraction of a second and is easy to miss if one looks away while turning the key. If the motion of the throttle location is witnessed then the test is over. 4. If there was no pre-start throttle location, Check the condition of the Li-ion batteries (section 3.2.2). If the batteries are faulty, replace them and repeat the test. 5. If the Li-ion batteries are OK, but the throttle failed to locate, then follow steps 1-7 of (section 5.1.1) to gain access to the inverter. Check the voltage of the red wire indicated in (Fig. 15), (do not confuse it with the red/white wire in the same connector). Pull the connector out of the inverter and put the positive test lead of the volt meter on the red wire, and the negative test lead on the black wire of the Li-ion battery connector (section 3.2.2, Fig.3). The voltage should match the LI-ion (battery voltage), V. If there is no, or low voltage, inspect the wiring harness for breaks or shorts. Repair them and repeat the test. Be sure to plug the connector back into the inverter after checking the voltage, and before checking the throttle location. Fig. 14 Fig If the voltage of the red wire matches the Li-ion (battery voltage), and the throttle still fails to go through the pre-start throttle location process, replace the inverter. Pull the two wire connector out of the inverter and check the voltage of the red wire. 27 PH3300i SM, Rev

28 4.3 Cylinder Compression Check Do not crank engine while touching the high tension wire (spark plug wire) as a severe shock could result. 1. Remove the maintenance door. 2. Remove the spark plug cap. 3. Remove the spark plug (use spark plug wrench from the supplied tool kit). 4. Install a compression gauge in the spark plug hole (Fig. 16). 5. 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 Fig. 16 Pressure Gauge 28 PH3300i SM, Rev

29 4.4 Ignition System This section deals with troubleshooting a faulty ignition system. This generator is equipped with Li-ion batteries that control the step motor during startup and provide auxiliary ignition power. The main battery requires a minimum of 10.5VDC and the lithium ion batteries require V to power the step motor properly. Before diagnosing an ignition problem, make sure the batteries are fully charged and the terminal connections are clean and tight (section 3.2). The generator uses a Capacitive Discharge Ignition. In a (CDI) system, a charging circuit charges a high voltage capacitor and at the instant of ignition the system stops charging the capacitor, allowing the capacitor to discharge its output to the ignition coil which sends the voltage to the spark plug. Check for spark (section 4.4.1). Clean, inspect and gap the plug (section 4.6). Plug gap: mm ( ). No spark Perform the spark test again using a new spark plug. No spark Check the 20A in-line fuse located on the battery power wire. Fuse good, no spark Test the ignition switch (section 4.4.3). No spark Disconnect the oil level sensor and perform spark test. No spark Check the ignition coil/trigger assembly and spark plug wire and cap resistance (section 4.4.2). No spark Check the trigger air gap (section 5.8). Normal, Still no spark Test the ignition power from the inverter (section ). Normal, Still no spark Check the harness wires to the ignition coil, trigger and ignition switch for breaks, shorts or bad connections. Good spark Blown fuse Abnormal Good spark Abnormal Abnormal Abnormal Abnormal Replace the faulty spark plug. Replace fuse. Check spark. Replace switch or repair as required. Test the oil level sensor (section 4.5.1). Replace or repair as required. Replace ignition coil or repair as required (section 5.8). Re-adjust the trigger air gap (section 5.8). Re-test spark. If spark not restored, replace trigger, reset gap, and re-test spark. Replace inverter (section ). Repair or replace wire harness as necessary. 29 PH3300i SM, Rev

30 4.4.1 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. 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 3.6). Clean or replace plug, as necessary before checking spark. Make sure you are using an F7RTC or equivalent spark plug. 4. Install the spark plug into the plug cap. 5. Attach a ground wire between the engine block and the negative (-) electrode (the steel body of the spark plug) (Fig.17). 6. 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. 18). 7. If there is no spark, or a weak spark; continue following the ignition troubleshooting flowchart. Ground Wire Fig. 17 Fig PH3300i SM, Rev

31 4.4.2 Ignition Coil/Trigger Assembly Inspection The ignition coil/trigger assembly (Fig. 20) is mounted on the engine block, above the rotor, under the inlet fan cover. It can be tested without removal from the unit using the procedure below. When bench testing the assembly, use the ground wire indicated in (Fig. 20) instead of chassis ground. See (section 5.8) for replacement of the ignition coil/trigger assembly. Primary resistance Secondary resistance Ω kΩ Trigger resistance Ω 1. Remove the control panel screws and carefully let it hang from its connections. Locate the 6-pin ignition coil/trigger connector, and unplug it from the wiring harness (Fig. 19). 2. Attach the two leads of the tester to the red wire and black wire and measure the primary resistance of the ignition coil. The primary coil resistance should be between Ω. 3. Check the red and black wire separately for continuity to chassis ground and the spark plug cap. 4. If the primary coil resistance is outside the specified range, or there is any continuity found in step 3, replace the ignition coil/trigger assembly. 5. To check the secondary resistance, attach one lead of the tester to chassis ground (or the ground wire of the ignition coil) and the other lead to the spark plug cap. The secondary coil resistance should be between kΩ. 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/trigger assembly if the secondary resistance is outside of the specified range. 8. Attach the two leads of the tester to the green/white wire and blue/white wire of the 6-pin connector to measure the resistance of the trigger coil. Trigger coil resistance should be Ω. 9. Check the green/white wire and blue/white wire separately for continuity to chassis ground. 10. If the trigger coil resistance is outside the specified range, or there is any continuity found in step 9, replace the ignition coil/trigger assembly. Black Ignition Wire Red Ignition Wire Ignition Coil Trigger Coil 6-Pin Connector Green/white Trigger Wire Blue/white Trigger Wire Ground Wire Fig. 20 Fig. 19 Spark Plug Cap 31 PH3300i SM, Rev

32 4.4.3 Ignition Switch Inspection Before beginning to test the ignition switch, make sure the batteries are fully charged and the terminal connections are clean and tight (section 3.2). 1. Remove the control panel to gain access to the back side of the ignition switch. 2. Find the 6-pin ignition switch connector behind the control panel as shown (Fig. 21). Disconnect it for the first part of the test. 3. In the OFF position there should be continuity (0Ω) between the black and pink wires only. 4. In the ON position there should be continuity (0Ω) between the red and orange wires only. 5. In the START position there should be continuity (0Ω) Fig. 21 between the red, orange and blue wires only. If the switch passes steps 3-5 then the ignition switch is good, continue to step 6 to test the ignition wiring. If the switch did not pass steps 3-5 replace the switch before continuing. 6. Reconnect the ignition switch for steps 6-8. Refer to the table below for the ignition wire voltages at the different ignition switch positions. In the OFF position verify that there is battery ground at the black and pink wires and that there is 12V positive (battery voltage) at the red wire. 7. Turn the switch to the ON position and verify that there is battery ground at the black wire and no ground at the pink wire. Verify that there is 12V positive (battery voltage) at the red and orange wires. 8. Turn the switch to the START position and verify that there is battery ground at the black wire and no ground at the pink wire. Verify that there is 12V positive (battery voltage) at the red, orange and blue wires (the starter should crank as well). If the switch has passed steps 6-8 then the ignition switch and the ignition switch wiring are good. If the switch passed steps 3-5, but failed one or more of steps 6-8 then look for a wiring problem in the ignition switch circuits. Wire Voltage at Different Switch Positions Ignition Switch Position Wire Color OFF ON START Black 0V (Gnd) 0V (Gnd) 0V (Gnd) Red 12 (Batt+) 12 (Batt+) 12 (Batt+) Orange 0V 12 (Batt+) 12 (Batt+) Blue 0V 0V 12 (Batt+) Pink 0V (Gnd) 0V 0V 32 PH3300i SM, Rev

33 4.5 Oil Level Sensor Fails to Stop Engine with Low Oil Completely drain the oil, disconnect the oil sensor wire connector, and check the continuity between the white wire and chassis ground (section 4.5.1). Continuity No continuity Check and repair all wire connections as necessary. Replace the oil level sensor if necessary (section 5.7 and 5.12). Follow step 1 in (section 4.13) to access the voltage regulator. Check the continuity of the white wire between the low oil sensor (section 4.5.1, Fig. 23) and the low oil sensor connector on the voltage regulator (section 4.13, Fig. 30). Continuity No continuity Repair or replace the wire between the low oil sensor and the voltage regulator. Verify that the voltage regulator supplies V to the ignition/indicator module when the white wire of the voltage regulator is grounded (section 4.13, step 6). Good Voltage No or low voltage Replace the voltage regulator. Check the continuity of the pink wire between the voltage regulator and the ignition/indicator (section 4.13, step 6). Continuity If the voltage from the voltage regulator is reaching the ignition/indicator module, and the engine is not being shut down and/or the low oil light is not being illuminated, then replace the ignition/indicator module. No continuity Repair or replace the wires between the voltage regulator and the ignition/indicator module. 33 PH3300i SM, Rev

34 4.5.1 Checking the Low Oil Sensor This generator is equipped with a low oil sensor that shuts down the engine when the oil reaches critical levels, to prevent engine failure. The low oil sensor is mounted inside the crankcase of the engine. If the oil sensor needs to be replaced, the crankcase will need to be opened. Refer to (section 5.7) for engine removal and (section 5.12) for opening the crankcase. 1. Remove the maintenance door and locate the oil sensor lead which is strapped to the battery wire harness below the in-line fuse between the battery and the air cleaner (Fig. 22). 2. Disconnect the low oil sensor while the engine is running (Fig. 23). 3. Ground the white wire from the regulator connector to the engine block, to verify that the engine stops and the low oil light on the control panel illuminates. If the engine fails to stop, or the low oil light fails to illuminate, refer to the flow chart in (section 4.5) to diagnose the problem. 4. After confirming that the engine oil is at the proper level, test for continuity between the white wire of oil sensor connector and the case of the engine (Fig. 24). No continuity indicates a normal condition. If there is any continuity at all, replace the oil sensor. 5. Continuity (.1 1.0Ω) between the white oil sensor lead and engine when the oil is drained from the engine indicates a normal condition. If there is high resistance, or no continuity replace the oil sensor Failure to replace a faulty oil level sensor can lead to permanent engine damage or destruction if the engine runs low of oil. Fig. 22 Fig. 23 White Connector to the Low Oil Sensor Low Oil Sensor Lead Behind In-line Fuse White Connector to the Regulator Fig. 24 Check Continuity between the White Oil Sensor Wire and Ground 34 PH3300i SM, Rev

35 4.6 Engine Stops Running Check the oil level (section 3.3). Sufficient oil Check the oil level sensor (section 4.5.1). Check fuel level. Sensor working Sufficient fuel Check the fuel valve, fuel filter (section 3.9), and fuel lines for blockage. Not blocked Check the fuel pump (section 4.6.1). Normal Check for spark (section 4.4.1). Good Spark Check BFP solenoid (section 5.1.3). Normal Low oil Faulty No fuel Blocked Faulty No/poor spark Abnormal Fill the oil reservoir to the proper level and restart the engine. Replace the oil level sensor (section 4.5.1). Add fuel and restart the engine. Clear the fuel valve and lines, replace the fuel filter (section 3.9). Replace the fuel pump (section 4.6.1). Test the ignition system (section 4.4). Replace the BFP solenoid (section 5.1.3). Check the carburetor gasket for leakage. Normal Abnormal Tighten carburetor bolts or replace gasket as required. Perform the throttle control system test (section ). Normal Abnormal Replace step motor (section ). Check trigger ignition coil/assembly (section 5.8). Normal Measure the cylinder compression (section 4.3). Abnormal Abnormal Readjust the trigger clearance (section 5.8). 1. Check the valve clearance (section 3.7). 2. Check head gasket. 3. Check for carbon deposits on the valves & combustion chamber. Clean as necessary. 4. Check the valve cone and seat (section ). Lap valves, or replace & regrind as necessary. 5. Check for worn piston, piston ring or cylinder (section ). Re-ring or overhaul as necessary. 35 PH3300i SM, Rev

36 4.6.1 Fuel Pump Testing This generator is equipped with a vacuum powered fuel pump that is mounted on a vertical frame member behind the front cover (Fig. 25). The vacuum that powers the fuel pump comes from a vacuum port on the insulator block between the carburetor and the engine. Before testing the fuel pump verify that the vacuum hose from the isolator block to the fuel pump is in good condition and has no leaks, blockages, or kinks. Replace the hose if necessary. Standard fuel line of the same size may be used if the OEM replacement hose is unavailable. 1. Disconnect the spark plug wire so that the engine will not start while conducting this test. 2. Follow steps 1-6 in (section 5.1.1) to gain access to the fuel pump behind the front cover (Fig. 25). Plug fuel lines as necessary. 3. Remove the fuel lines from the inlet and outlet of the fuel pump, but leave the vacuum line attached. 4. Remove the screws that hold the fuel pump to the frame, and carefully allow the fuel pump to hang in front of the inverter from its vacuum line. 5. Using two spare pieces of fuel line, 6-8 long, attach one on the inlet and one on the outlet of the fuel pump (Fig. 26). 6. Find a small open container that will safely hold a few ounces of fuel to a depth of Put the fuel in it, and place it so the fuel line from the pump inlet is completely below the surface of the fuel. 7. Hold the fuel line from the pump outlet over the edge of the container, so that any fuel being pumped back into the container will be clearly visible. 8. Turn the ignition key to the START position and hold it there while watching the end of the fuel line from the fuel pump outlet. Within 3-5 seconds there should be fuel flowing back into the container in gentle pulses timed with the revolutions of the engine. This indicates that the fuel pump is working properly. 9. If after 10 seconds of cranking there is no fuel present replace the fuel pump. Fuel Pump Fig. 25 Fig. 26 Fuel Pump Inlet To Vacuum Port Fuel Pump Outlet 36 PH3300i SM, Rev

37 4.7 Engine Speed Cannot Increase or is Hunting Check the fuel filter, fuel valve, fuel lines, Blocked Replace fuel filter (section 3.9). Clean and tank strainer for blockage or lines, valve, and strainer as necessary. restrictions. Not blocked Check the air filter element for blockage. Blocked Clean the air filter element (section 3.5). Not blocked Inspect spark arrestor for carbon buildup (section 3.10). Not blocked Blocked Remove and clean carbon deposits (section 3.10). Remove and inspect the spark plug (section 3.6). Check for spark (section 4.4.1). Normal Check the carburetor for blockage (section 5.1.1). No blockage Check the carburetor gasket and vacuum lines for leakage. Normal Measure the cylinder compression (section 4.3). Normal Perform the throttle control system test (section 5.1.2). Abnormal Blocked Abnormal Abnormal If spark is weak or erratic refer to (section 4.4). Clean or replace spark plug as necessary. Disassemble and clear (section 5.1.5, Fig. 43). Replace vacuum lines or carburetor gasket as required (section 5.1.1). 1. Check the valve clearance (section 3.7). 2. Check head gasket. 3. Check for carbon deposits on the valves & combustion chamber. Clean as necessary. 4. Check the valve cone and seat (section ). Lap valves, or replace & regrind as necessary. 5. Check for worn piston, piston ring or cylinder (section ). Re-ring or overhaul as necessary. 4.8 Engine Speed Too High This generator has been designed to prevent the engine from overspeed revving. Overspeed revving occurs when a generator s on-board monitoring systems detect a drop in voltage from the inverter, and the generator attempts to compensate by revving the engine higher to generate more electricity. In the rare event of an inverter failure, there will be no voltage output from the inverter, and the engine will remain revving at or close to its top speed. In the event this happens, the engine will be shut down by the overspeed protection. If the engine overspeeds and then shuts down, restart the engine and check the AC output. Check the AC output. Normal Check the carburetor gasket and vacuum lines for leakage. Normal Check the throttle control step motor (section ). Normal Replace the inverter. (section ). Abnormal Abnormal Abnormal No or low AC output and perform the recommended diagnostics (section 4.9). Replace vacuum lines or carburetor gasket as required. (section 5.1.1). Replace the throttle control step motor (section ). 37 PH3300i SM, Rev

38 4.9 No or Low AC Output This generator is equipped with a low voltage shutdown feature. If conditions are such that the engine begins to bog down before enough power is produced for the inverter to overload, the voltage will begin to fall as the engine loses speed. When this happens the low voltage protection will turn on the overload light, and shutdown the inverter to protect delicate electronic equipment. When the inverter has been shut down due to low voltage, it cannot be reset with the rest button on the control panel. The unit must be shut down with the key and restarted to restore AC power output. Is the Overload Indicator light on? No Check all circuit breakers. Are any of them tripped? Not tripped Stop the engine and check the AC receptacles for burnt contacts and loose or burnt connections. Normal Yes Tripped Abnormal Disconnect the load and press the overload reset button. If the inverter fails to reset, test reset button and wires to inverter. If reset button and wires are OK, replace inverter (section 5.10). Disconnect the load and reset the breakers. Replace the AC receptacles if necessary. Check to see if the engine feels jammed or seized upon being shut down. Engine jammed Inspect the rotor magnets for damage, replace the rotor if damaged (section 5.9). Measure the stator output voltage while running (section 4.10), and the stator winding resistance (section 5.9.1). Normal Replace inverter (section 5.10). Engine turns normally Abnormal Inspect and repair stator wire harness or replace stator (section 5.9.2). Check cylinder for foreign objects. 38 PH3300i SM, Rev

39 4.10 Measuring Stator Main Output Voltage While Running Before conducting this test turn the ignition key ON and OFF. This will pre-set the throttle in the proper position for starting the generator. This will prevent engine overspeeding due to the throttle being left wide open during shutdown. 1. Remove the 6 control panel screws, carefully allowing it to hang out of the way. 2. Remove the maintenance door and disconnect the carburetor step motor connector. On some models it is necessary to follow steps 1-7 in (section 5.1.1) because the step motor connector is routed all the way to the inverter and cannot be accessed from the maintenance door. 3. Find and unplug the connector from the inverter and start the engine (Fig. 27). It will be necessary to manually adjust the throttle to make the engine run in the upper RPM range ( RPM) before checking the stator main output voltage. Once set, do not alter the throttle during the rest of the test. 4. Check voltage between pins 1 & 4, between pins 2 & 4 and between pins 1 & 2 (Fig. 28). There should be approximately VAC at each test. The three readings should be approximately equal within ±25VAC. 5. If one or more of the three tests fail, the problem is either a damaged wire harness or a defective stator/rotor. Check the wire harness for damage, and repair and retest if necessary. 6. If it has been verified that there are no wiring issues, then the stator/rotor is faulty and will need to be replaced. If all these tests are OK but there is still no or low voltage, the inverter will need to be replaced (section ). To 120VAC Output Fig. 27 To 6-Pin Stator Connector Fig Pin Stator Connector White Sub Windings 3 & Black Phase Wires 1, 2 & 4 39 PH3300i SM, Rev

40 4.11 No DC Output At Battery Charge Receptacle Check the DC circuit breaker. Normal Abnormal Reset DC circuit breaker if tripped. Check continuity through breaker, replace if faulty. Find the 9-pin connector from the voltage regulator (section 4.13). With the generator running, verify that there is 13-15V on the red-black wire (section 4.13, Fig. 28). Abnormal Inspect wires of the 9-pin connector from the voltage regulator for breaks and shorts (section 4.13, Fig. 28), and check continuity through to the DC receptacle. Repair as necessary. If there are no wiring issues, replace voltage regulator Starting Battery Will Not Charge Before troubleshooting, inspect battery condition (section 3.2). Inspect the battery terminals & quick disconnect connections. Normal Check the DC voltage at the battery and the control panel with the generator running. See steps 1 and 2 on the following page. Normal With the generator running, unplug the stator low voltage winding from the voltage regulator. Measure the voltage between the blue wires (section 4.4.3, Fig. 21). Voltage: 16-20VAC Normal Replace the voltage regulator. Abnormal 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. Check all wire connections of the voltage regulator. Test the voltage (section 4.13). Check the wiring harness for breaks or shorts, repair as necessary. If no wiring issues found, replace the stator (section 5.8). 40 PH3300i SM, Rev

41 4.13 Voltage Regulator Testing The voltage regulator provides three different isolated voltage sources. The first is the charging voltage for the 12V starting battery, which uses the negative battery terminal and chassis ground as its ground reference. The second is the 12VDC output for the control panel, which also uses chassis ground as a ground reference. The third voltage is the charging voltage for the 3.6V Li-ion batteries, which uses the black wire from the voltage regulator as a ground reference. In the following tests it is important to measure the voltages between the wires designated in the test procedures. If chassis ground is used as a ground reference in every test, then the voltage reading for the Li-ion battery charging voltage, and the oil alarm signal, will be false readings. 1. To access the voltage regulator, follow steps 1-7 in (section 5.1.1). After conducting the voltage regulator tests, reassembly using the steps in the reverse order. 2. With the generator running, unplug the stator low voltage winding from the voltage regulator. Measure the voltage between the blue wires (Fig. 29). The voltage should be 16-20VAC. If the voltage is good, reconnect the stator and voltage regulator and continue the test. If the voltage does not fall within this range then replace the stator (section 5.9.2). 3. With the generator running and all voltage regulator connections connected, perform the following steps: a. Measure the starting battery charging voltage from the voltage regulator 9-pin connector (Fig. 30). Put the voltmeter positive test lead on the red wire, and the negative test lead on the yellow/green wire. The voltage should be VDC, depending on the condition of the starting battery. If the voltage does not fall within this range, replace the voltage regulator. b. Measure the control panel DC output voltage from the voltage regulator 9-pin connector. Put the voltmeter positive test lead on the red/black wire, and the negative test lead on the yellow/green wire. The voltage should be VDC. If the voltage does not fall within this range, replace the voltage regulator. c. Measure the Li-ion battery charging voltage from the voltage regulator 9-pin connector. Put the voltmeter positive test lead on the red/white wire, and the negative test lead on the black wire. The voltage should be VDC, depending on the condition of the Li-ion batteries. If the voltage does not fall within this range, replace the voltage regulator. 4. With the engine running, disconnect the low oil sensor connector to test the voltage regulator low oil sensor response. Leave the 9-pin and stator connector connected. Put the voltmeter positive test lead on the pink wire, and the negative test lead on the black wire of the 9-pin connector. Using a jumper wire connect the white wire from the voltage regulator low oil sensor connector to the engine block. The voltmeter should change from 0VDC to VDC, and the engine should die. If neither of these things happens, replace the voltage regulator. If the voltage changes, but the engine does not die, then look for a break or short in the pink wire between the voltage regulator and the ignition/indicator module on the control panel. If the pink wire has good continuity, but the engine still does not die and/or the low oil light does not illuminate when the white wire is grounded, replace the ignition/indicator module. Fig. 29 Low Voltage Windings Fig pin Connector To Wiring To the Voltage Regulator To Low Oil Sensor To Stator 41 PH3300i SM, Rev

42 4.14 Engine Runs-on or Backfires After Being Turned Off This generator is equipped with a backfire prevention solenoid (BFP) on the bottom of the carburetor bowl that is activated to shut off the fuel for several seconds during shutdown. If the engine is running-on or backfiring after being turned off the BFP system needs to be tested. Follow the procedure below. 1. Remove the control panel and carefully let it hang from its connections. 2. Disconnect the BFP connector behind the control panel (section 5.1.3, Fig. 38). 3. Test for continuity between the green/white wire in the end of the BFP connector that goes back into the harness and the green/white wire coming from the ignition/indicator module. If there is no continuity you will need to repair or replace the green/white wire between the ignition/indicator module and the BFP connector. 4. Test for continuity between the black wire in the end of the BFP connector that goes back into the harness and the black wire coming from the ignition/indicator module. If there is no continuity you will need to repair or replace the black wire between the ignition/indicator module and the BFP connector. 5. Start the engine. 6. To test if the BFP is being activated after shutdown use a voltmeter and connect the positive lead of the voltmeter to the green/white wire and the negative lead to the black wire of the end of the BFP connector from the ignition/indicator module. 7. While the engine is running the voltage should be 0-1VDC. When the ignition switch is turned off the voltage should read 12-14VDC for 1-3 seconds. If the voltage does not go up to 12-14VDC after the key is turned off, replace the ignition/indicator module. 8. If there were no issues found with continuity of the green/white or black wires, and the voltage was 12-14VDC for 1-3 seconds after shutdown, then test the BFP solenoid (section 5.1.3). 9. Replace the BFP solenoid if necessary (section 5.1.3) Engine Will Start Then Shut Down Check the low oil light. No low oil light Low oil light Check engine oil level. Sometimes the oil level can be just above the critical shutoff level before starting, and drop below the shutoff level once started due to oil splash. Add oil if necessary. If engine overspeeds briefly and then shuts down and has no AC output; then it is overspeeding due to inverter failure. Overspeeds Replace the inverter (section 5.10). 42 PH3300i SM, Rev

43 5. REPAIR 5.1 Carburetor Removal / Installation of Carburetor Drain all gasoline from the fuel tank and the carburetor (Fig. 31) before disassembly. Keep the unit away from all heat, flame and sparks. 1. Remove the maintenance door and disconnect the battery. 2. Disconnect the manual choke cable from the carburetor by loosening the screws shown in (Fig. 32). It is not necessary to completely remove the screws. 3. Remove the control panel, carefully allowing it to hang out of the way. 4. Disconnect the fuel hoses from the fuel valve, plug them if necessary. 5. Remove the front lift handle. 6. Remove the six front cover screws and remove the front cover. Carefully maneuver the control panel back through the control panel hole in the front cover. 7. Remove inverter bolts and carefully lay the inverter on its back. 8. Remove the two screws from the air filter cartridge and slide it out of the air cleaner. 9. Remove the two screws from the charcoal canister and move it out of the way to gain access to the air cleaner. 10. Remove the six air cover screws, disconnect the Li-ion battery connector, and take off the air cleaner cover. 11. Remove two nuts from the carburetor studs and remove the air cleaner. 12. Disconnect the step motor connector. 13. Remove the carburetor as an assembly by sliding it off its studs. 14. Reinstall the carburetor using these steps in reverse order. Fig. 33 Fig. 31 Choke Cable Hold-down Screw Fig. 32 Choke Cable Adjustment Screw Air Filter Cartridge Air Cleaner Cover Carburetor Air Cleaner 43 PH3300i SM, Rev

44 5.1.2 Throttle Control Step Motor Remove and inspect the step motor if troubleshooting procedures have indicated it may be faulty. Before removing the step motor, inspect the inside of the carburetor to make sure there are no physical obstructions that would prevent the free motion of the throttle plate Removal / Installation of Step Motor 1. Remove the carburetor by following steps 1-13 in (section 5.1.1). 2. Unplug the step motor. 3. Take care not to dislodge the fork and fork spring located below the step motor bracket (Fig. 35). The spring is under compression and can be easily lost if not controlled. Remove the two step motor screws and carefully remove the step motor (Fig. 34). It is not necessary to remove the step motor bracket, or the choke cable mount, to change the step motor. Leave the bracket and choke cable mount on, and hold the fork and spring in place with a flat bladed screwdriver when pulling the step motor away from its bracket. 4. Carefully align the flats on the shaft of the replacement step motor with the flats of the fork (indicated by an arrow in (Fig. 35) when reinstalling the motor. 5. Reinstall the carburetor using the steps in (section 5.1.1) in reverse order. Step Motor Step Motor Bracket Fig. 34 Choke Cable Mount Fig. 35 Choke Cable Mount Standoffs Fork Fork Spring 44 PH3300i SM, Rev

45 Resistance and Backlash of Step Motor Before checking the resistance, carefully rotate the step motor shaft back and forth between your thumb and forefinger to check the backlash of the step motor gears. There should be almost none. If the backlash is in excess of mm ( ) then replace the step motor. 1. Measure the resistance of the outlet terminals of the step motor (Fig. 36). Resistance value Pin 1-blue - Pin 2-white: Ω Pin 3-red - Pin 4-black: Ω 2. Replace the step motor if the resistance does not fall within the recommended range. Fig PH3300i SM, Rev

46 5.1.3 Backfire Prevention Solenoid (BFP) The backfire prevention solenoid is located on the bottom of the carburetor bowl. Its purpose is to shut off the fuel when the engine is turned off to prevent post-shutdown backfire and run-on (dieseling). If the backfire prevention solenoid is suspected of being faulty, measure the resistance between the leads as detailed below. 1. Measure the resistance of backfire prevention solenoid between the two leads of the green connector (Fig. 37). This connector can be accessed by removing the control panel (Fig. 38). 2. To bench test the BFP solenoid drain the carburetor float bowl, unscrew the BFP and remove it from the carburetor. The needle on the end of the solenoid should be in the retracted position (Fig. 39). Apply +12V to one of the solenoid leads, and ground to the other (polarity does not matter). The solenoid should make a click noise, and the needle should move to the extended position (Fig. 39). 3. Replace the BFP if the resistance does not fall within the specified range, or it fails the bench test. Make sure the end of the needle is clean before installing. Resistance value 7-9Ω Measure resistance between these pins. Fig. 37 Access BFP connector behind control panel. Fig. 38 Retracted Fig. 39 Extended 46 PH3300i SM, Rev

47 5.1.4 Manual Choke Assembly The manual choke is activated by a cable mounted on the front panel, next to the control panel, and above the fuel valve. It has 4 positions; FULL (Fig. 42), ¾, ½, and OFF (Fig. 41). It is mounted and adjusted properly from the factory, but the end of the cable attached to the carburetor must be disconnected in order to take off the front panel. Care must be taken when reconnecting the cable so it is adjusted properly. If the cable is not adjusted properly the choke may not be completely open in the OFF position, or the choke may not be fully closed in the FULL position. If the choke is not completely seated in its detent in the FULL position, then the choke can wiggle off slightly during the starting process. This can cause hard starting in extremely cold conditions. Follow the procedures below for disconnecting and reconnecting the choke cable. Choke Cable Hold-down Screw Fig. 40 Choke Cable Adjustment Screw Disconnecting the Choke Cable 1. Remove the maintenance door and disconnect the battery. 2. Disconnect the manual choke cable from the carburetor by loosening the screws shown in (Fig. 40). It is not necessary to completely remove the screws Reconnecting the Choke Cable When reinstalling the front panel, make sure that the choke cable is routed so it is free, and can be attached to the carburetor without restriction. Without a cable attached to the choke, it is spring loaded in the OFF position (OPEN). It should be in this position at the start of this procedure. 1. Thread the end of the choke cable through the cable hold-down and then through the eye of the cable adjustment ferrule (Fig. 41). 2. Put the threaded fitting on the end of the choke cable case under the cable hold-down until it firmly seats against the stop on the mount, see red circle in (Fig. 41). Tighten the choke cable hold-down screw. 3. Push the choke knob down firmly and pull on the end of the cable to remove any slack. Tighten down the choke cable adjustment screw. Verify the choke is still in the OFF position (OPEN). 4. Pull the choke knob all the way out to the FULL choke position and verify that the choke is fully closed (Fig. 42). Crank the starter, and pull the recoil starter several times while carefully watching the choke to make sure the knob does not move and the choke remains in the FULL choke position. If the choke moves off while cranking, adjust a very small amount of slack from the cable and retest. Choke Cable Adjustment Ferrule Choke in OFF position Choke in FULL position Fig. 41 Fig. 42 Choke Cable Hold-down Screw 47 PH3300i SM, Rev

48 5.1.5 High Altitude Jet The OEM jet that comes installed in the factory carburetor will provide optimal performance to an altitude of 6000 feet. It is unnecessary to change to a high altitude jet for altitudes 6000 feet. Fig. 43 Rubber Bowl Seal Fuel Bowl Emulsifier Tube Main Jet O-Rings BFP Solenoid Fuel Bowl Retainer 48 PH3300i SM, Rev

49 5.2 Control Panel Disassembly / Installation Fig. 44 Remove Mounting Screws (6) Fig V-20 & 30 amp Circuit Breakers Ignition Switch 12V DC Circuit Breaker Indicator Module Module Cover 12V Receptacle Hour Meter 120V 20amp Duplex (5-20) 120V 30amp (L5-30) Overload Reset Button Ignition Key USB Ports 49 PH3300i SM, Rev

50 5.3 Outer Generator Housing Disassembly / Installation Fig. 46 Gas Cap Rubber Grommet Top Cover Fuel Gauge Sight Glass Rubber Grommet Gas Tank Upper Frame Fuel Pump Carbon Canister Lift Handle Right Cover Handle Sponge Oil Access Cover Fold Over Handle Exhaust Grille Rear Cover Starting Battery DC Voltage Regulator Starter Solenoid Lift Handle Short Sponge Front Cover Inverter Choke Knob Maintenance Door Left Cover Fixed Wheels Swivel Wheels Fuel Knob Control Panel 50 PH3300i SM, Rev

51 5.4 Recoil Starter Disassembly / Reassembly 1. Remove the maintenance door and disconnect the battery. 2. Disconnect the manual choke cable from the carburetor (section 5.1.1, Fig. 32). 3. Remove the control panel, carefully allowing it to hang out of the way. 4. Disconnect the fuel hoses from the fuel valve, plug them if necessary. 5. Remove the front lift handle. 6. Remove the six front cover screws and remove the front cover. Carefully maneuver the control panel back through the control panel hole in the front cover while removing it. Set the front panel aside, and carefully allow the control panel to hang out of the way (Fig.47). 7. Remove inverter bolts and carefully lay the inverter on its back (Fig. 48). 8. Remove the three M6 flange bolts (circled in Fig. 48) and remove the recoil starter. 9. Reinstall all components in reverse order. Fig. 47 Recoil Starter Charcoal Canister Fuel Pump Li-ion Batteries Inverter Fig. 48 Recoil Starter Inverter 51 PH3300i SM, Rev

52 5.5 Starter motor Starter Testing Before beginning to test the starter, make sure the battery is fully charged and the terminal connections are clean and tight (section 3.2.1). 1. Follow steps 1-6 in (section 5.1.1) to remove the front panel. 2. Remove the rear end panel and the right side panel. 3. Disconnect the cable from the starter relay (Fig. 49). 4. Attach a 10 to 12 gauge jumper cable to the positive battery terminal of sufficient length to reach the starter motor. It is important that the jumper wire be attached to the battery first and not the starter so that any potential sparks that may be generated during this process are not near the battery. Make sure the unconnected end of the jumper cable does not come in contact with the chassis ground. Touch the unconnected end of the jumper to the starter connection for the starter relay cable. The starter should engage the ring gear and turn the engine at a normal cranking speed. If it fails to engage the ring gear, fails to crank or cranks very slowly, or produces excessive heat or smoke, replace the starter (section 5.5.2). 5. If the starter passes step 4, reconnect the cable from the starter relay. Turn the ignition key to the START position and verify that the starter performs as well as it did in step 4. If not, check the cable from the starter relay for breaks, shorts or bad connections (section 5.6). Cable from Starter Relay Fig. 49 Starter Motor 52 PH3300i SM, Rev

53 5.5.2 Starter Removal / Replacement 1. Follow steps 1-6 in (section 5.1.1) to remove the front panel. 2. Remove the rear lift handle and the rear end panel. 3. Disconnect the battery. Remove the right side panel. The recoil rope can be left in the hole in the panel. Pull the rope, with the panel, very slowly until there is enough slack in the rope to set the panel down out of the way. 4. Remove the cable coming from the starter relay. 5. Remove the three screws and two M6 bolts from the starter access cover and remove the cover (Fig. 52). It may be necessary to remove the bolts holding the upper frame to the base to allow the fuel tank to be moved up slightly to gain access to the bolt indicated with a dotted circle. Also note that the cover is colored orange for the purposes of this manual, but is black in production. 6. Remove the two M8 starter bolts (Fig. 53) and remove the starter. Slowly turn the engine, by hand, through a full 360 turn, while examining the ring gear. If the ring gear has sections of teeth badly worn or missing replace the rotor (section 5.9.2). 7. Replace the starter using these steps in reverse order. Fig. 52 Fig. 53 M6 Intake Fan Cover Bolts Cable from Starter Relay #2 Phillips Screws M8 Starter Motor Bolts 53 PH3300i SM, Rev

54 5.6 Starter Relay The starter relay is bolted to the chassis next to the voltage regulator, behind the inverter, and beneath the recoil starter, as shown in (Fig. 54). Before beginning to test the starter relay, make sure the starting battery is fully charged and the terminal connections are clean and tight (section 3.2.1). Follow the 5 steps below to gain access to the starter relay. The starter relay can be tested on or off the generator. 1. Follow steps 1-7 in (section 5.1.1) for removing the carburetor. Fig After conducting the starter relay tests, re-assembly using the steps in the reverse order. Starter Relay Fig Testing Starter Relay on Generator 1. First verify that the starter relay has good chassis ground. The relay body is grounded through its mounting bolts. Make sure the mounting bolts have good electrical contact with the chassis. It may be necessary to remove the paint around the mounting hole to accomplish this. 2. Verify that there is 12V positive (battery voltage) at the battery terminal of the starter relay (Fig. 55). If not, clean battery connections or repair wiring as necessary to restore battery power to the battery terminal. Verify that there is no continuity between the battery and starter motor terminals of the starter relay. 3. Turn the ignition key to the START position. Verify that there is 12V (battery voltage) being supplied to the spade terminal marked Start Wire from Ignition Switch in (Fig. 55). If there is, the relay should make a single clicking sound, there should then be continuity between the battery and starter motor terminals of the starter relay, and the starter is turning, the relay is good. 4. If the ignition switch failed to supply 12V (battery voltage) to the relay then test the ignition switch for the cause of the problem (section 4.4.3) and continue this test using a jumper wire. Connect the jumper wire from the 12V positive terminal of the battery to the spade terminal of the relay (from step 3). The relay should click, there should be continuity between the battery and starter motor terminals, and the starter should be turning. If there is no continuity between the battery and starter terminals, the relay needs to be replaced. 5. If there is continuity between the terminals but the starter fails to turn, check the wire between the relay and the starter (Fig. 56) for breaks, shorts or dirty/loose connections. Repair as necessary. If power is being supplied by the relay to the starter but the starter fails to operate properly see (section 5.5) for starter service. Battery Terminal Starter motor Terminal Cable from Starter Relay Fig. 56 Start Wire from Ignition Switch Chassis Ground Starter Motor 54 PH3300i SM, Rev

55 5.6.2 Bench Testing the Starter Relay 1. Using a volt-ohm meter, check the resistances of the electromagnetic coil of the starter relay by connecting the red positive lead to the ¼ spade and the black negative lead to the metal body of the relay (Fig. 57). Resistance Ω 2. Check the function of the start relay by connecting the ¼ spade terminal to the 12V positive battery terminal. Connect the metal base or body to the negative battery terminal. There should be a clicking sound as the relay is activated. While the relay remains activated, use the volt-ohm meter to check continuity between the two lugs (Fig. 58). If there is no continuity the relay is defective. There must only be continuity between the battery and starter terminals when the relay is activated. Fig. 57 Checking Resistance Fig. 58 Checking Continuity Connect to negative battery terminal Connect to 12V positive battery terminal 55 PH3300i SM, Rev

56 5.7 Intake Fan Cover Drain all gasoline from the fuel tank before disassembly. Keep the unit away from all heat, flame and sparks. 1. Follow steps 1-7 in (section 5.1.1) to remove the front panel and inverter. 2. Remove the charcoal canister. 3. Remove the rear end panel and the left and right side panels. 4. Remove the upper frame and the gas tank as an assembly (Fig. 59). 5. Disconnect all wires from the stator assembly. 6. Disconnect the starter motor wire and all ground wires. 7. Remove 4 nuts from the engine mounting bolts (2 on each side) and lift the engine assembly off the base pan (Fig. 60 & 61). 8. Remove the carburetor and the intake fan cover, revealing the engine (Fig. 62). Upper Frame and Gas Tank Fig. 59 Fig. 60 Mounting Bolts Fig PH3300i SM, Rev

57 Fig. 62 Intake Fan Cover Bolts Intake Fan Cover Bolt Intake Fan Cover Bolt 57 PH3300i SM, Rev

58 5.8 Ignition Coil/Trigger Assembly Adjustment / Replacement 1. Follow steps 1 through 8 as outlined in (section 5.7) (Intake fan cover). 2. Check the clearance between the trigger and the TDC block of the rotor by inserting a feeler gauge ( ) between them (Fig. 63). If the gap is correct there should be only slight resistance felt when sliding the feeler gauge in between them. Adjust if necessary (step 3). 3. Loosen the ignition coil & trigger mount bolts (circled in Fig. 63) and insert the feeler gauge. Allow the magnetic tip of the trigger to contact the feeler gauge and retighten the bolts. Recheck the gap, re-adjust if necessary. 4. Rotate the rotor to make sure there is no interference with any other components. 5. Reverse the procedure to reassemble. Trigger clearance mm ( ) Fig. 63 Ignition Coil Trigger Feeler Gauge Rotor TDC Block 58 PH3300i SM, Rev

59 5.9 Stator and Rotor Stator Inspection 1. Follow steps 1-7 in (section 5.1.1) for removing the front panel and inverter. 2. Locate the 6-pin harness (Fig. 64) near the inverter and unplug it. 3. Locate the two pin connector (Fig. 64) from the stator and unplug it from the voltage regulator. DC charging windings Measure the resistance between the two blue terminals at the 2-pin connector. Resistance Blue-Blue Ω Sub windings Measure the resistance between the two sub winding terminals at the 6-pin connector. Resistance White-White Ω Main windings Measure the resistance between each of the main winding terminals at the 6-pin connector (Fig. 64). Resistance Black-Black-Black Ω Fig Pin Connector from Stator to 6-Pin harness on Inverter 2-Pin Connector from Stator to Voltage Regulator 59 PH3300i SM, Rev

60 5.9.2 Stator Removal and Reassembly Drain all gasoline from the fuel tank before disassembly. Keep the unit away from all heat, flame and sparks. 1. Follow steps 1-7 in (section 6.1) for removing the front panel and inverter. 2. Remove the rear end panel and left and right side panels (section 5.3). 3. Remove the upper frame and the fuel tank as an assembly (section 5.7, Fig. 59). 4. Disconnect all wires from the stator assembly. 5. Disconnect the starter motor wire and all ground wires, remove the starter (section 5.5.2, Fig. 52 & 53). 6. Remove 4 nuts from the engine mounting bolts (2 on each side) and lift the engine assembly off the base pan (section 5.7, Fig. 60 & 61). 7. Remove the carburetor and the intake fan cover. 8. Remove the ignition coil/trigger assembly, starter cup and fan (Fig. 65). 9. Remove the M16 flange nut from the crankshaft (Fig. 65). 10. Attach an appropriate puller to the rotor using three M6X1 bolts (grade 8.8 or better) and remove the rotor (Fig. 66). 11. Remove the cable retainer clip and 4 stator mounting bolts using an M5 Allen wrench (Fig. 67). 12. Reverse the procedure to reassemble. Fig. 65 Stator Stator Bolts Rotor Flange Nut Intake fan Starter Cup Ignition Coil/Trigger Assembly Fig. 66 Fig. 67 M6X1 Bolts Cable Retainer Clip and Bolt 60 PH3300i SM, Rev

61 5.10 Inverter Inspection / Adjustment / Replacement The inverter is mounted near the front edge the base plate (chassis) between the frame uprights behind the front cover. The performance specifications are given below. Check the inverter output at the 120VAC receptacles on the control panel using a volt meter, and power meter or ammeter. If the no/low load primary output voltage is out of range, or the inverter is overloading below the maximum output, then the inverter needs to be adjusted or replaced. Note that replacement inverter output should be checked as it may need minor adjustments before being put into service. Steps for the adjustment and replacement of the inverter are detailed below. Inverter Performance Specifications Output Voltage (0-400W load) VAC, 58-62Hz Rated Output (continuous) Maximum Output (for > 2 minutes) Minimum Output Before Overload 3200W(30A)@ VAC, 58-62Hz 3300W(33.3A)@ VAC, 58-62Hz 3350W(33.75A)@ VAC, 58-62Hz Inverter Removal / Preparation for Adjustment 1. Follow steps 1-7 in (section 5.1.1) to remove the front panel and gain inverter access. 2. Carefully lay the inverter on its back (Fig. 68). If the inverter is being replaced, disconnect the connections from the faulty inverter and connect the new one in its place. Set the inverter and control panel on a flat, nonconductive surface as shown so there is no stress on the wires or connections. Fig. 68 Inverter, Ready for Adjustment Control Panel 61 PH3300i SM, Rev

62 Inverter Adjustment / Replacement When setting the overload adjustment pot, the inverter will warm up rapidly due to the lack of forced airflow. Do not run the unit for more than 5 minutes while setting the overload adjustment pot. Have all your test equipment ready before starting this step and conduct this adjustment expeditiously. Only adjust the two adjustment pots referenced in these procedures. All other adjustments are set at the factory and should not be adjusted under any circumstances. 1. Complete steps 1-7 in (section 5.1.1) for removing the front panel and inverter. 2. Connect a volt meter to one of the 120V 20A duplex receptacles (5-20R). Connect a load bank and power meter (or ammeter if you don t have a power meter) to the 120V L5-30 receptacle. 3. Start the generator. 4. Adjust the voltage to 122V ±0.3 by turning the voltage adjustment pot screw (Fig. 70) clockwise to increase and counter-clockwise to decrease. 5. Using a load bank and power meter set the overload adjustment pot (Fig. 71) to trip at 3350W W. Set it to trip at 27.9A 28.1A if you are using an ammeter instead of a power meter. Turn the adjustment screw clockwise to increase and counter-clockwise to decrease. 6. Shut the generator off. 7. Seal the screws on both adjustment pots using a drop of touch up paint or silicone sealant. 8. Reassemble the generator using steps 1-7 in (section 5.1.1) in reverse order. Fig. 69 Voltage Adjustment Pot Fig. 70 Overload Adjustment Pot Fig PH3300i SM, Rev

63 Inverter Ignition Power The inverter supplies power to the ignition/indicator module for the CDI ignition system. During normal running conditions the stator is providing the energy to the inverter for running the ignition power. During start up the engine RPM may not be adequate to provide all the necessary energy, so the inverter relies on the Li-ion ignition batteries and the starting battery for the necessary energy to run the ignition power. It is still possible to start the generator without the help of the batteries, but it requires a vigorous pull on the recoil starter to get sufficient engine RPM to get the power from the stator. When diagnosing a no spark condition, it may be necessary to verify that the inverter is supplying the necessary power to the ignition/indicator module. The procedure for doing this is below. 1. Follow the troubleshooting chart in (section 4.4) for diagnosing ignition problems. It is important to have verified starting and Li-ion battery condition and proper operation of the ignition switch and the low oil sensor before beginning this test. 2. Follow steps 1-7 in (section 5.1.1) to access the inverter. Lay the inverter down (Fig. 72). 3. Check the continuity from the red/white wire (Fig. 72) to the red/white of the ignition/indicator module on the control panel. The resistance should be Ω. If the resistance is not in this range then repair or replace this wire before continuing. 4. Check the continuity of the black wire from the Li-ion battery tray (section 3.2.2, Fig. 3) to the 8-pin receptacle on the inverter shown in (Fig. 73). If the resistance is not Ω, then repair the wiring to restore good ground to the inverter before continuing. 5. With the ignition key ON, put the positive test lead of the volt meter on the red wire (Fig. 72), and the negative lead on the black wire of the 8-pin connector on the receptacle (Fig. 73). Verify that the voltage is V. If there is no or low voltage refer to (section 3.2.2) and (section 4.13) and restore good (battery voltage), or replace the voltage regulator as necessary. 6. With the ignition key ON, put the positive test lead of the volt meter on the red/white wire (Fig. 72), and the negative lead on the black wire of the 8-pin connector on the receptacle (Fig. 73). Verify that the voltage is V. If there is no or low voltage replace the inverter. Fig. 72 Red Wire from Voltage Regulator/Li-ion Batteries Check Black Ground Wire from this 8-pin Receptacle Fig. 73 Red/White Wire to Ignition/Indicator Module 63 PH3300i SM, Rev

64 5.11 Muffler Removal / Replacement Muffler removal and installation must be performed with the engine cold. Drain all gasoline from the fuel tank before disassembly. Keep the unit away from all heat, flame and sparks. 1. Remove the maintenance door and disconnect the battery. 2. Disconnect the manual choke cable from the carburetor by loosening the screws shown in (Fig. 32) of (section 5.1.1). It is not necessary to completely remove the screws. 3. Remove the control panel, carefully allowing it to hang out of the way. 4. Disconnect the fuel hoses from the fuel valve, plug them if necessary. 5. Remove the front lift handle, and then the six front cover screws. Remove the front cover. Carefully maneuver the control panel back through the control panel hole in the front cover. 6. Remove the rear end panel, the side panels, and the top cover, reference the Outer Generator Housing exploded view in (section 5.3). 7. Remove upper frame, with fuel tank, as one assembly (Fig. 74). 8. Remove the muffler cover bolts and remove the muffler cover (Fig. 75). 9. Remove the muffler bolts. Carefully note the placement of the various length bolts and spacers during removal for reassembly (Fig. 76). 10. Remove the muffler. This gains access to secondary air valve and exhaust fan (Fig. 77). Upper Frame and Gas Tank Muffler Cover Bolts Fig. 74 Fig. 75 Gasket Long Spacer M8x80 Exhaust Fan M8x90 Short Spacer M8x170 M8x150 Fig. 76 Fig. 77 Secondary Air Valve 64 PH3300i SM, Rev

65 5.12 Engine Exploded View 65 PH3300i SM, Rev

66 PH3300 Engine 177F Ref # MFR # Stock Description Drain Bolt Drain Bolt Gasket Crankcase, 177F Crankcase Gasket Crankcase Pin M10 Serrated Flange Nut Low Oil Sensor M6 X 16 Flange Bolt, Zinc Connecting Rod Assy (Bolt M8 x 40) Connecting Rod Assy (Cap) Connecting Rod Assy (Rod) Crankshaft Bearing Oil Dipstick O-Ring, Dipstick Cover, Crankcase Oil Seal M8 X 35 Flange Bolt Piston Pin Clip Piston Pin Piston Piston Ring Set (5) Second Piston Ring Top Piston Ring Camshaft Assy Head Gasket Valve Lifter Valve Push Rod Pin, Cylinder Head Intake Valve Exhaust Valve Stud, M8 X Cylinder Head Exhaust Manifold Stud Guide Plate Valve Adjusting Stud Rocker Arm 66 PH3300i SM, Rev

67 Adjustment Nut Valve Adjusting Jam Nut Valve Spring Washer Valve Spring Intake Valve Spring Retainer Exhaust Valve Spring Retainer Valve Adjustment Spacer Spark Plug, F7RTC M10 x 80 Flange Bolt Gasket, Valve Cover, 177F Cover, Valve Seal, Valve Cover Washer Valve Cover Bolt, R1 67 PH3300i SM, Rev

68 5.13 Cylinder Head / Valves Cylinder Head Removal Drain all gasoline from the fuel tank before disassembly. Keep the unit away from all heat, flame and sparks. 1. Follow steps 1-6 in (section 5.1.1) to remove the front panel. 2. Remove the rear end panel and the left and right side panels. 3. Remove the upper frame and the fuel tank as an assembly. 4. Remove the inverter (section ). 5. Remove the air cleaner and carburetor (section 5.1.1). 6. Remove the intake fan cover (section 5.7). 7. Remove the muffler cover, muffler, exhaust fan, exhaust manifold and muffler case (Fig. 78, 79, 80). 8. Remove the upper and lower engine covers (Fig. 81). 9. Remove the valve cover and 4 - M10 head bolts (Fig. 82). Muffler Cover Muffler Case Fig. 78 Fig. 79 Muffler Exhaust Manifold Fig. 80 Fig. 81 Upper Engine cover Exhaust Fan Lower Engine cover 68 PH3300i SM, Rev

69 Fig. 82 Valve Cover Cylinder Head Alignment Sleeves Valve Cover Bolt and Rubber Seal Valve Cover Gasket Cylinder Head Head Gasket Cylinder Head Disassembly and Reassembly Fig. 83 Rocker Arms Rocker Arm Studs Valve Spring Retainers Push Rods Cylinder Head Intake Valve Jam Nuts Rocker Arm Adjustment Nuts Guide Plate Lash Pad Valve Springs Exhaust Valve 69 PH3300i SM, Rev

70 Valve and Spring Inspection Free Length Of Valve Spring Standard Service limit 39.1mm (1.54 ) 37.5mm (1.48 ) Valve Seat Width Standard Service limit 0.8mm (0.03 ) 1.8mm (0.07 ) Valve Stem Outer Diameter Standard Service limit Intake valve mm ( ) 6.40mm (0.252 ) Exhaust valve mm ( ) 6.40mm (0.252 ) 70 PH3300i SM, Rev

71 5.14 Crankshaft / Camshaft / Piston Disassembly and Reassembly Piston and Rod Front Engine Seal Front Crankshaft Bearing Lifters Key Low Oil Sensor Crankshaft Rod Bolts Lower Rod Cap 71 PH3300i SM, Rev

72 Alignment of Timing Marks Use marks to align camshaft gear and timing gear during installation. Fig. 84 Timing Marks Cam Gear Crankshaft Gear 72 PH3300i SM, Rev