PH2400PRiE - Service Manual PDF

POWERHOUSE ®
PH2400PRi/E Digital Inverter Generator

SERVICE MANUAL
PREFACE
This manual covers the construction, function and servicing procedure of the POWERHOUSE®
PH2400PRi/E generator, certificated by CARB.
Careful observance of these instructions will result in better, safer service work.
All information, illustrations, directions and specifications included in this publication are based on the
latest product information available at the time of approval for printing. LKQ Specialty Products Group
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 PH2400PRi/E Owner’s Manual before using this
Service Manual.
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CONTENTS
PREFACE ..................................................................................................................................................... 2
CONTENTS .................................................................................................................................................. 3
1. SPECIFICATIONS.................................................................................................................................... 5
1.1 Specifications ............................................................................................................................................. 5
1.2 Characteristics ........................................................................................................................................... 6
1.3 Wiring Diagram .......................................................................................................................................... 7
2 SERVICE INFORMATION......................................................................................................................... 8
2.1 The Importance of Proper Servicing .......................................................................................................... 8
2.2 Important Safety Precautions .................................................................................................................... 8
2.3 Servicing Rules .......................................................................................................................................... 9
2.4 Electrical Precautions ................................................................................................................................ 9
2.5 Serial Number Location ........................................................................................................................... 10
2.6 Engine Maintenance Standards............................................................................................................... 11
2.7 Alternator Electrical Specifications (Stator Windings) ............................................................................. 12
2.8 Torque Values.......................................................................................................................................... 12
3. MAINTENANCE ..................................................................................................................................... 13
3.1 Maintenance Schedule ............................................................................................................................ 13
3.2 Battery Maintenance ................................................................................................................................ 14
3.3 Checking the Oil Level ............................................................................................................................. 15
3.4 Changing Oil ............................................................................................................................................ 16
3.5 Air Filter Inspection and Cleaning ............................................................................................................ 17
3.6 Spark Plug Inspection and Cleaning ....................................................................................................... 18
3.7 Valve Clearance Inspection and Adjustment ........................................................................................... 19
3.8 Evaporation Control ................................................................................................................................. 21
3.9 Fuel Filter Replacement........................................................................................................................... 22
3.10 Spark Arrestor ........................................................................................................................................ 23
4. TROUBLESHOOTING ........................................................................................................................... 24
4.1 Battery Charge Requirements ................................................................................................................. 24
4.2 Starter Does Not Crank ........................................................................................................................... 25
4.3 Hard Starting ............................................................................................................................................ 26
4.4 Cylinder Compression Check .................................................................................................................. 27
4.5 Ignition System ........................................................................................................................................ 28
4.5.1 Checking for Spark .......................................................................................................................................... 29
4.5.2 Ignition Coil Inspection .................................................................................................................................... 30
4.5.3 Ignition Switch Inspection ................................................................................................................................ 31
4.6 Oil Level Sensor Fails to Stop Engine with Low Oil................................................................................. 32
4.6.1 Checking the Low Oil Sensor .......................................................................................................................... 33
4.7 Engine Stops Running ............................................................................................................................. 34
4.8 Engine Speed Cannot Increase or is Hunting ......................................................................................... 35
4.9 Engine Speed Too High ........................................................................................................................... 36
4.10 No or Low AC Output. ............................................................................................................................ 37
4.11 Measuring Stator Main Output Voltage While Running ......................................................................... 38
4.12 No DC Output at Battery Charge Receptacle. ....................................................................................... 39
4.13 Battery Will Not Charge ......................................................................................................................... 39
4.14 Voltage Regulator Testing ..................................................................................................................... 40
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4.15 Engine Will Start Then Shut Down ........................................................................................................ 41
4.16 Engine Will Not Start or Stop with Remote ............................................................................................ 41
4.17 No Output When Operating in Parallel ................................................................................................... 42
4.17.1 Parallel Operating Procedure and Overload Reset ....................................................................................... 42
4.17.2 Troubleshooting Parallel Operation ............................................................................................................... 44
5. REPAIR .................................................................................................................................................. 45
5.1 Electronic Fuel Injection (EFI) .................................................................................................................. 45
5.1.1 Overview of EFI System .................................................................................................................................. 45
5.1.2 Engine Control Unit (ECU) .............................................................................................................................. 46
5.1.3 Fault Codes ..................................................................................................................................................... 47
5.1.4 Manifold Air Pressure Sensor (MAP) ............................................................................................................... 49
5.1.5 Oxygen Sensor (O2) ........................................................................................................................................ 51
5.1.6 Temperature Sensor ........................................................................................................................................ 53
5.1.7 Crankshaft Position Sensor (CPS) .................................................................................................................. 54
5.1.8 Fuel Injector ..................................................................................................................................................... 55
5.1.9 Fuel Pump/Gauge Assembly ........................................................................................................................... 57
5.1.10 Intake Manifold .............................................................................................................................................. 60
5.1.11 Throttle Control – Step Motor ......................................................................................................................... 61
5.2 Control Panel ........................................................................................................................................... 62
5.2.1 Disassembly / Installation ................................................................................................................................ 62
5.2.2 Digital Display .................................................................................................................................................. 63
5.3 Removing Outer Case ............................................................................................................................. 67
5.4 Outer Generator Housing ........................................................................................................................ 69
5.4.1 Outer Housing Exploded View ......................................................................................................................... 69
5.5 Recoil Starter ........................................................................................................................................... 70
5.5.1 Recoil Starter / Removal / Replacement.......................................................................................................... 70
5.6 Starter Motor ............................................................................................................................................ 71
5.6.1 Starter Testing ................................................................................................................................................. 71
5.6.2 Starter Removal/Replacement ........................................................................................................................ 72
5.7 Starter Relay ............................................................................................................................................ 73
5.7.1 Testing the Starter Relay on the Generator ..................................................................................................... 73
5.7.2 Bench Testing the Starter Relay ...................................................................................................................... 74
5.8 Intake Fan Cover Removal/Replacement ................................................................................................ 75
5.9 Stator and Rotor ....................................................................................................................................... 76
5.9.1 Stator Inspection ............................................................................................................................................. 76
5.9.2 Stator Removal / Replacement ........................................................................................................................ 77
5.10 Inverter Inspection / Adjustment / Replacement .................................................................................... 78
5.10.1 Inverter Removal / Preparation for Adjustment .............................................................................................. 78
5.10.2 Inverter Adjustment / Replacement................................................................................................................ 79
5.11 Muffler Removal / Replacement ............................................................................................................ 80
5.12 Exploded Engine View ........................................................................................................................... 81
5.13 Valve Cover / Rocker Arm ..................................................................................................................... 85
5.13.1 Removal / Disassembly ................................................................................................................................. 85
5.13.2 Rocker Arm Inspection .................................................................................................................................. 86
5.14 Cam and Cylinder Head ........................................................................................................................ 87
5.14.1 Inspection / Reassembly ............................................................................................................................... 87
5.14.2 Cylinder Head Reassembly ........................................................................................................................... 88
5.14.3 Reinstalling the Timing Chain Tensioner ........................................................................................................ 89
5.14.4 Valves and Valve Spring Inspection ............................................................................................................... 89
5.15 Piston / Connection Rod / Cylinder ........................................................................................................ 91
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1. SPECIFICATIONS
1.1 Specifications
Dimensions and weights
Model PH2400PRi-E
Overall Length 22 in. (559mm)
Overall Width 12 in. (305mm)
Overall Height 19.5 in. (495mm)
Net Weight, with battery 88.4 lbs. (40.1kg)
Engine
Model 152F
Type 4-stroke, OHC, single cylinder, gasoline engine
Displacement 125cc
Bore x stroke 52.4 Χ 57.8mm
Maximum horsepower 4.35hp
Compression ratio 9.2:1
Cooling system Forced Air-Cooled
Ignition system Capacitor Discharge Ignition (CDI)
Spark plug A7RTC
Fuel System EFI (Electronic Fuel Injection)
Air cleaner Semi-dry type
Governor Electronic control type
Lubrication system Oil Pump
SAE 10W-30 (SF/SG grade or greater) above 0°C (32°F)
Lube oil
SAE 0W-30 / 0W-40 below 0°C (32°F)
Oil capacity 15.6 oz. (460 ml)
Starting system Remote, Electric, & Recoil
Stopping system Electrical Fuel Cut-off
Recommended Fuel Automotive unleaded gasoline
Alternator
Alternator type Multi pole rotation type
Alternator structure Self-ventilation drip-proof type
Excitation Self-excitation (Magnet type)
Phase Single phase
Rotating direction Clockwise (Viewed from the generator)
Frequency regulation AC-DC-AC conversion (Inverter type)
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1.2 Characteristics
Model PH2400PRi-E
Maximum output AC 2.4kW
Rated output AC 2.3kW
Rated output DC 100W
Rated frequency 60HZ
Rated voltage AC 120V
Rated voltage DC 12V
Rated current AC 19.2A
Rated current DC 8.3A
Power factor 1.0cosφ
Voltage variation rate 10% max.
Momentary average 1.5% max.
Average time 3 sec. max.
Voltage stability ±1%
Frequency variation rate 1% max.
Momentary average 1% max.
Average time 1 sec. max.
Frequency stability ±0.1%
Insulation resistance 10MΩ min.
AC circuit protector 20A
DC circuit protector 10A
Fuel tank capacity 1.2 gal (4.7L)
Continuous running time
2.8 / 6.3 hours
(at rated load / at 1/4 load)
Noise level (Zero load to full load) 61 - 72 dBA @ 23ft/7m
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1.3 Wiring Diagram
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2 SERVICE INFORMATION
2.1 The Importance of Proper Servicing
Proper servicing is essential to the safety of the operator and the reliability of the engine. Any error or
oversight made by the technician while servicing can easily result in faulty operation, damage to the
engine or injury to the operator.
▪ Improper servicing can cause an unsafe condition that can lead to serious injury
or death.
▪ Follow the procedures and precautions in this service manual carefully.
▪ Some of the most important precautions are given below. However, we cannot
warn 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.
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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, and seals 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 with a tube or by wrapping with an insulating tape. If the wire harness has a
grommet, install the grommet securely.
10. Take care not to pinch the wire harnesses during installation of a part. If a wire harness has
damaged insulation, repair by winding with the electrician’s insulating tape.
11. Before using test equipment, carefully read the manufacturer’s instructions and follow the
instructions in this Service Manual. Be sure that the test equipment battery is fully charged and
verify that the unit is operating correctly before you begin testing.
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2.5 Serial Number Location
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 LKQ Specialty Products Group for warranty administration and must be supplied before
any work can be done.
The BCN is found in two locations:

1. On the side of the generator, beside the lower left corner of the maintenance door (Fig 1-A).
2. On the outside of the shipping carton (Fig 1-B).
The ESN can be found stamped on the engine block above the oil dipstick. It is visible when the
maintenance door is removed (Fig. 1-C).
Fig. 1-A Fig. 1-C
Fig. 1-B
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2.6 Engine Maintenance Standards
Specification Service limit
Part Item
mm (in) mm (in)
Engine Maximum speed without load 5000±100rpm —
52.400-52.420mm 52.505mm
Cylinder Bore I.D.
(2.0630”-2.0638”) (2.0671”)
52.360-52.380mm 52.25mm
Skirt O.D
(2.061”-2.062”) (2.057”)
Piston
15.002-15.008mm 15.050mm
Pin bore I.D.
(0.5906”-0.5909”) (0.5925”)
14.994-15.000mm 14.950mm
Piston pin O.D
(0.5903”-0.5905”) (0.5886”)
0.97-0.99mm 0.87mm
Height h
(0.0382”-0.0390”) (0.0343”)
0.02-0.06mm 0.15mm
Ring side clearance
(0.0008”-0.0024”) (0.0059”)
1st ring
0.15-0.25mm 1.0mm
Ring end clearance
(0.006”-0.010”) (0.039”)
1.90-2.10mm 1.80mm
Width t
(0.0748”-0.0826”) (0.0590”)
0.97-0.99mm 0.87mm
Height h
(0.0382”-0.0390”) (0.0343”)
0.02-0.06mm 0.15mm
Ring side clearance
(0.0008”-0.0024”) (0.0059”)
Piston ring 2nd ring
0.15-0.25mm 1.0mm
Ring end clearance
(0.006”-0.010”) (0.039”)
2.0-2.3mm 1.8mm
Width t
(0.0787”-0.0905”) (0.059”)
1.85-1.96mm 1.75mm
Height h
(0.0728”-0.0772”) (0.0689”)
0.03-0.18mm 0.24mm
Ring side clearance
(0.001”-0.007”) (0.009”)
Oil ring
0.20-0.50mm 1.0mm
Ring end clearance
(0.008”-0.020”) (0.039”)
2.05 - 2.35mm 1.9mm
Width t
(0.0807”-0.0925”) (0.075”)
15.006 －
Connecting 15.08mm
Small end I.D 15.017mm
rod (0.594”)
(0.590”-0.591”)
0.10±0.02mm
IN
Valve (0.004”±0.001”)
---
clearance 0.15±0.02mm
EX
(0.006”±0.001”)
Valves
4.975-4.990mm 4.92mm
IN
(0.1958”-0.1964”) (0.1937”)
Stem O.D.
4.955—4.970mm 4.90mm
EX
(0.1950”-0.1951”) (0.193”)
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Specification Service limit
Part Item
mm (in) mm (in)
5.000-5.030mm 5.06mm
Guide I.D. IN/EX
(0.197”-0.198”) (0.199”)
Valves
1.0mm 2.0mm
Seat width IN/EX
(0.039”) (0.079”)
35.5mm 33.8mm
Outer spring
(1.397”) (1.330”)
Valve Spring Free length
32.8mm 31.1mm
Inner spring
(1.291”) (1.224”)
29.026-29.086mm 28.5mm
Cam Lobe Cam height
(1.143”-1.145”) (1.104”)
0.6-0.7mm
Spark plug Gap —
(0.024”-0.028”)
Primary side 4.0-5.0Ω —
Ignition coil Resistance
Second side 16.5-19.0kΩ —
Trigger coil Resistance 113-130Ω —
2.7 Alternator Electrical Specifications (Stator Windings)

Part Item Wire color Specifications(Ω)
DC winding Resistance blue－blue 0.25-1.00 Ω
Sub winding Resistance white－white 0.10-1.00 Ω
Main winding Resistance black－black－black 0.20-2.00 Ω
2.8 Torque Values

Tightening torque
Item Specification
lbs-ft N·m
Connection rod bolt (not serviceable) N/A N/A
Spark plug M10-1x13mm 7-9 10-12
Crankcase cover M6-1 7-9 10-12
Flywheel nut M12-1.25 52-59 70-80
M5 Bolt, nut 4-5 5-7
Standard torque M6 Blot, nut 6-7 8-10
M8 Bolt, nut 13-16 18-22
▪ Use standard torque values for fasteners that are not listed in this table.
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3. MAINTENANCE
3.1 Maintenance Schedule
Regular Service period. Perform at every indicated month or operating hour

interval, whichever occurs first.
Maintenance
Item
Procedure
First Month Every 3 Months Every 6 Months Every Year
Each Use
or 4-6 HRS or 50 HRS or 100 HRS or 300 HRS
Check O
Engine Oil
Change O O
Check O
Air cleaner
Clean O (1)
Clean / Adjust O
Spark Plug
The spark plug will last longer in a generator that runs at varying loads. If you always run
Replace
the generator at the same load, you will need to replace the spark plug more frequently.
Spark Arrester Clean O
Check O
Fuel Filter
Replace O (2)
Fuel tank & strainer Clean O (2)
Fuel Injector Clean Add fuel injector cleaner to the fuel tank every 100 hours.
Fuel line Check Every 2-years (Replace as necessary) (3)
Valve clearance Check / Adjust O (3)
Charge monthly during long term storage.
12V 5Ah AGM Battery Clean - Charge Check terminals for corrosion monthly, clean as needed.
Expected battery life is 2 years, but can be affected by operating environment.
Notes:
(1) Service more frequently when operating in dusty areas, every 10 hours or every day.
(2) Service more frequently under extreme cold or hot weather, and dusty conditions. Replace filter
and clean tank and strainer immediately after any cases of fuel contamination.
(3) Service should be performed by a POWERHOUSE® authorized agency, unless correct tools and
a professional specialist are available. Service should always be performed according to the
Service Manual.
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3.2 Battery Maintenance
This generator comes equipped with 12V, 5Ah, AGM battery located behind the battery access door.
During frequent use, the generator will maintain proper battery charge. Refer to (section 4.12) if the
battery is not being charged properly under frequent usage.
It is recommended that the battery be fully charged before starting any diagnostic work on the
generator. This generator is equipped with an ECU, fuel pump and other EFI components that
require 10.5VDC minimum voltage to run properly. The battery must have a charge of at least
10.5VDC while being cranked to be able to start the generator. If the battery has a charge in the
range of 10-10.5VDC, the generator may crank well, but the starter will be drawing most of the
power and will cause a large enough drop in voltage that the EFI system will not work properly. If the
battery is at or near the 10.5VDC threshold it may still be possible to start the generator with the
recoil starter, as this does not cause a voltage drop during the starting process. However, this is why
it is recommended the battery be fully charged before doing any diagnostic work on the generator.
During storage periods, charge the battery monthly. To avoid battery damage from overcharging, use
a charger with an automatic shut-off feature and use a maximum 5A setting for charging this battery.
If this battery appears swollen or damaged, replace it. It is recommended that the battery be
replaced with the exact OEM replacement battery. Do not replace this battery with one that has less
than a 5Ah capacity.
Follow the steps below for removal of the battery.
1. On the left side of the generator, remove the battery access door.
2. Unplug the quick connect harness indicated in Fig. 2.
3. Press the down the battery hold-down clasp to unhook it from the battery box (Fig. 2).
4. Turn the battery hold down strap sideways, and then feed it back between the red and black
battery cables, onto the top of the battery.
▪ Do not allow the metal battery hold-down clasp or hoop to touch across the two
battery terminals, as this will short the battery.
5. Slide the battery out of the battery box (Fig. 3).

6. Replace the battery using these steps in reverse order.
Quick Connect
Harness
Fig. 2 Fig. 3
Battery Hold-down
Clasp
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3.3 Checking the Oil Level
▪ Verify that the engine is off and the generator is on a level surface before
checking oil level.
1. Remove the maintenance door.

2. Remove the oil dipstick and wipe clean. Check the oil level by re-inserting the dipstick to the end
of the threaded portion of the dipstick (Fig. 4).
3. If the oil level is low, add oil until it reaches the upper level on the dipstick.
4. Re-install the dipstick and the maintenance door before restarting the generator.
Fig. 4 Oil Dipstick
Re-insert to
this line to
check oil level
Upper level
Lower level
Oil Reservoir
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3.4 Changing Oil
▪ Make sure to turn the ignition switch OFF before draining.
▪ Drain the oil while the engine is still warm to assure rapid and complete draining.

2. Remove the oil dipstick.
3. Install the oil drain pipe by threading it in the dipstick hole (Fig 5).
4. Drain the dirty oil into a container. Allow enough time for the oil to drain thoroughly.
5. Refill with the recommended oil, and check the oil level.
6. Reinstall the maintenance door and tighten the screw securely.
Engine oil capacity: 15.6 oz. (460 ml)

Fig. 5
Re-insert to
this line to
check oil level
Upper level
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.
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3.5 Air Filter Inspection and Cleaning
1. Remove the maintenance door (Fig. 6)
2. Remove the air filter cover.
3. Remove the filter element from the air filter case.
4. Inspect the filter element.
5. 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).
6. If the element is dirty, wash the filter element in a soapy water solution, rinse, and let it dry
thoroughly.
7. Reinstall the filter element and the air filter cover. Tighten the cover screw securely.
8. Reinstall the maintenance door.
Fig. 6
Air Filter Cover Air Filter Case
Maintenance
door
Air Filter
Element
▪ 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.
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3.6 Spark Plug Inspection and Cleaning Fig. 7
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 fuel delivery issue. Ash deposits are
evidence of oil burning under normal combustion NEW NORMAL WORN
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 5.13, 5.14 & 5.15). Oil burning
can also be caused by a faulty PCV valve (built into the
LEAN FLOODED Ash deposits -
valve cover). This will cause large amounts of engine oil to Burning oil
get pulled through the PCV hose, collect in the air cleaner,
and get sucked into the throttle body. If this is the case, try
replacing the PCV valve (valve cover).
2. Remove carbon or other deposits with a plug cleaner or Carbon– Too Rich Oil Fouled
stiff wire brush. Check the sealing washer for damage.
Spark Plug Type A7RTC
3. Measure the plug resistance; replace the spark plug if the resistance is outside of these values.
Spark Plug Resistance 3 - 9 kΩ
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.
0.6 – 0.7mm
Spark Plug Gap 0.6 - 0.7mm (0.024” - 0.028”)
5. Install the plug finger tight to seat the washer and then tighten with a plug wrench. Torque the
spark plug to 10-12Nm (7-9ft-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 10-12 Nm (7-9 ft-lbs)
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3.7 Valve Clearance Inspection and Adjustment
▪ Valve clearance inspection and adjustment must be performed with the engine
cold.
1. Remove the battery access door and disconnect the battery (section 3.2).
2. Remove the outer case (section 5.3).
3. Remove the two intake manifold flange bolts and take it off as a complete assembly. (see section
5.1.11).
4. Remove the carbon canister, starter motor, engine covers and muffler following steps 4-7 in
section 5.11.
5. Remove the valve cover (Fig 8).
Fig. 8
Valve
Cover
6. Turn the engine to set the piston at top dead center of the compression stroke. The timing mark
on the camshaft should be vertical to the cylinder head seal (Fig. 9). Verify that the intake and
exhaust valves are closed.
Fig. 9
Timing
Mark
19 PH2400PRi/E SM, Rev. 2019-02-13

7. Choose the recommended feeler gauge from the table below and insert it between the rocker
arm and the valve to check the valve clearance (Fig. 10).
Intake 0.10±0.02mm (0.004”±0.001”)

Valve Clearance
Exhaust 0.15±0.02mm (0.006”±0.001)
8. If adjustment is necessary, proceed as follows.

a. Loosen the adjusting screw lock nut and adjust the adjusting screw in or out until the desired
valve clearance is attained.
b. Secure the adjusting screw with a socket wrench and tighten the lock nut to the specified
torque.
c. After tightening the lock nut, check the valve clearance again.
9. Clean the cylinder block and valve cover surfaces.
Fig. 10
Adjustment
Screw
Lock Nut
Feeler Gauge
10. Replace the rubber seal (Fig. 11).
11. Install the removed parts in the reverse order of removal.
Fig. 11
Rubber
Seal
20 PH2400PRi/E SM, Rev. 2019-02-13

3.8 Evaporation Control
The evaporative control system is shown below (Fig. 12). The 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. 12
Fuel Tank Vent
To Air Filter
Air Filter
Fuel Tank
Assembly
Carbon Canister
21 PH2400PRi/E SM, Rev. 2019-02-13

3.9 Fuel Filter Replacement
▪ 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 fuel injector.
1. Verify the ignition is OFF and the battery is disconnected.

2. Remove the maintenance door and find the fuel filter (Fig. 13 & Fig. 14).
3. Remove hose clamps and remove fuel filter.
4. Reassemble in reverse order of disassembly.
Fig. 13
Fig. 14
22 PH2400PRi/E SM, Rev. 2019-02-13

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 four M6 screws and remove the muffler grill (Fig. 15).
2. Remove the two M4 screws holding the spark arrester to the muffler (Fig. 15).
3. Use a stiff wire brush to remove carbon deposits from the spark arrester screen.
4. Inspect the screen for holes and replace it if necessary.
Fig. 15 Spark Arrestor Muffler Grille
M4 Screws
M6 Screws
23 PH2400PRi/E SM, Rev. 2019-02-13

4. TROUBLESHOOTING
Troubleshooting Section Legend

4.1 Battery Charge Requirements
4.2 Starter Does Not Crank
4.3 Hard Starting
4.4 Cylinder Compression Check
4.5 Ignition System
4.6 Oil Level Sensor Fails to Stop Engine with Low Oil
4.7 Engine Stops Running
4.8 Engine Speed Can’t Increase, or is Hunting
4.9 Engine Speed Too High
4.10 No or Low AC Output
4.11 Measuring Stator Main Output Voltage While Running
4.12 No DC Output at Battery Charge Receptacle
4.13 Battery Will Not Charge
4.14 Voltage Regulator Testing
4.15 Engine Will Start Then Shuts Down
4.16 Engine Will Not Start or Stop With Remote
4.17 No Output When Operating in Parallel
4.1 Battery Charge Requirements

It is recommended that the battery be fully charged before starting any diagnostic work on the
generator.
This generator is equipped with an ECU, fuel pump and other EFI components that require 10.5VDC
minimum voltage to run properly. The battery must have a charge of at least 10.5VDC while being
cranked to be able to start the generator. If the battery has a charge in the range of 10-10.5VDC, the
generator may crank well, but the starter will be drawing most of the power and will cause a large
enough drop in voltage that the EFI system will not work properly. If the battery is at or near the
10.5VDC threshold it may still be possible to start the generator with the recoil starter, as this does
not cause a voltage drop during the starting process. However, this is why it is recommended the
battery be fully charged before doing any diagnostic work on the generator.
This generator comes equipped with 12V, 5Ah, AGM battery. This battery will be damaged by
improper charging or overcharging. To avoid battery damage from overcharging, use a charger with
an automatic shut-off feature and use a maximum 5A setting for charging this battery.
If the battery appears swollen or damaged, replace it. Do not replace this battery with one that has a
lower reserve capacity. It is recommended that the battery be replaced with the exact OEM
replacement battery.
24 PH2400PRi/E SM, Rev. 2019-02-13

4.2 Starter Does Not Crank
Make sure the battery is in good Charge the battery using recommended
condition and fully charged (section Abnormal charger. Do a load test to make sure the
3.2.1). Inspect the battery terminal battery maintains adequate voltage under
connections. load. Clean battery terminals. Replace
the battery if necessary.
Normal
Verify the remote switch is in the OFF ON Turn remote switch OFF. Verify the
position. remote switch contacts are open.
OFF
Check the 20A in-line fuse located on the Blown

Replace fuse.
battery power wire.
Normal
Abnormal Replace ignition switch and/or repair

Check the ignition switch (section 4.5.3). wiring faults found.
Normal
Repair ground. Clean wire ends and

Check the ground between the battery Abnormal battery terminals. Remove paint, dirt, oil
negative terminal and the starter relay
& grease, or corrosion from chassis
body, the engine block, and control panel.
grounds.
Normal
Abnormal Replace the starter relay (section 5.7).
Check the starter relay (section 5.7).
Normal
Inspect the starter motor wire and Abnormal If starter fails to operate properly replace
connection. Test the starter motor (section
the starter motor (section 5.6).
5.6).
25 PH2400PRi/E SM, Rev. 2019-02-13

4.3 Hard Starting
Charge battery using recommended

Make sure battery is in good condition charger. Do a load test to make sure the
Abnormal
and fully charged. Refer to section 4.1. battery maintains adequate voltage under
Inspect the battery terminal connections. load. Clean battery terminals. Replace
Normal battery if necessary.
Check the fuel level. No fuel

Add fuel and start the engine.
Sufficient fuel
Low oil
Check the oil level. Add oil and start the engine.
Normal
Check the fuel filter and fuel lines for Blocked Replace fuel filter or lines. See section
blockage. See section 3.9. 3.9.
Normal
Refer to section 5.1.3 for code
Check fault codes. See section 5.1.3. Codes found
descriptions. Go to appropriate section
No codes for testing based on code description.
Worn or
Remove and inspect the spark plug for a fouled plug Clean or replace spark plug and perform
worn, wet or fouled electrode. See any service recommended in section 3.6
section 3.6 for details. based on plug deposits.
Good spark plug No spark or
weak spark Refer to ignition troubleshooting section
Check for spark. See section 4.5.1.
4.5. Perform necessary tests and repairs.
Good spark
Faulty fuel
pump
Check fuel pump. See section 5.1.9. Replace or repair fuel pump as required.
Normal Faulty fuel
injector
Check fuel injector. See sections 5.1.8 Clean or replace fuel injector as required.
Normal
Abnormal Replace MAP sensor or repair as
Inspect MAP sensor. See section 5.1.4.
detailed in section 5.1.4.
Normal
Inspect the Crankshaft Position Sensor. Abnormal Replace Crankshaft Position Sensor or
See section 5.1.7. repair as detailed in section 5.1.7.
Normal
Low
cylinder 1. Check the valve clearance (section
Perform compression test as detailed in compression 3.7).
section 4.4. 2. Check for carbon deposits on the
Normal valves & combustion chamber. Clean
compression as necessary.
3. Check the valve cone and seat (section
Install the spark plug securely. Engine 5.14). Lap valves, or replace & regrind
should now start and run. as necessary.
4. Check for worn piston, piston ring or
cylinder (section 5.15). Re-ring or
overhaul as necessary.
26 PH2400PRi/E SM, Rev. 2019-02-13

4.4 Cylinder Compression Check
▪ Do not crank engine while touching the spark plug wire as a severe shock
could result.
1. Remove the spark plug access 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 65 psi (0.45Mpa) 800rpm
Fig. 16
Compression
Gauge
27 PH2400PRi/E SM, Rev. 2019-02-13

4.5 Ignition System
This section deals with troubleshooting a faulty ignition system. The EFI system of this generator
requires that the battery has a minimum of 10.5VDC during cranking. Before diagnosing an ignition
problem, make sure the battery is 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 per section 4.5.1. Clean,

inspect and gap the plug per section 3.6.
Plug gap: 0.6-0.7mm (0.024”-0.028”).
No spark
Good
Perform the spark test again using a new spark
Replace the faulty spark plug.
spark plug.
No spark
Check the 20A in-line fuse located on the Blown fuse

battery power wire. Replace fuse. Check spark.
Fuse good, no spark
Abnormal
Test the ignition switch. See section 4.5.3. Replace switch or repair as required.
No spark
Good
spark Test the oil level sensor per procedure in
Disconnect the oil level sensor and
section 4.6.1. Replace or repair as
perform spark test.
required.
No spark
Check the ignition coil, and spark plug Abnormal Replace ignition coil or repair as
wire and cap resistance. See section
required.
4.5.2.
No spark
Check the resistance of the Crankshaft Abnormal Replace the Crankshaft Position Sensor
Position Sensor (CPS). Section 5.1.7.1. (CPS). See section 5.1.7.2.
Normal,
Still no spark
Check the Crankshaft Position Sensor air Abnormal Readjust the Crankshaft Position Sensor
gap. See section 5.1.7.2. air gap. See section 5.1.7.2.
Normal,
Still no spark
Check the harness wires from the ignition Abnormal Repair or replace wire harness as
coil, CPS, ignition switch, and ECU for
necessary.
breaks, shorts, or bad connections.
Normal, Still no
Still no spark spark A problem with the wire harness has
Replace ECU. Spark should be restored. been overlooked. Repeat inspection of
the wire harness.
28 PH2400PRi/E SM, Rev. 2019-02-13

4.5.1 Checking for Spark
▪ Don’t pull the recoil starter or turn the ignition switch to “START” while
touching the spark plug wire.
1. Fill the oil reservoir to the correct operational level to ensure that the low oil sensor is not
inhibiting the spark.
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 A7RTC 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) as shown in (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 system troubleshooting
flowchart.
Fig. 17
Fig. 18
Ground Wire
29 PH2400PRi/E SM, Rev. 2019-02-13

4.5.2 Ignition Coil Inspection
Before beginning to test the ignition coil, make sure the battery is fully charged and the terminal
connections are clean and tight. See section 4.1 for battery charge requirements. The ignition
coil (Fig. 19) is mounted on the edge of the generator base plate, just a couple inches in front of
the maintenance door. It can be tested without removal from the unit using the procedure below.
Primary resistance 4.0-5.0Ω

Secondary resistance 16.5-19.0kΩ
1. Remove the maintenance door. Locate the white 2-pin ignition coil connector with a red-
black wire and blue-white wire near the air cleaner (Fig.20), and disconnect it.
2. Attach the two leads of the ohm tester to the red-black wire and blue-white wire and measure
the primary resistance of the ignition coil. The primary coil resistance should be between 4.0-
5.0Ω (shown above).
3. Check for continuity between the blue wire with white stripe, the red wire with black stripe,
the spark wire and either coil mount. There should be no continuity between any of these
wires and either coil mount.
4. If the primary coil resistance is outside the specified range, or there is continuity found
between any of the wires and either coil mount tested in step 3, replace the ignition coil.
5. To check the secondary resistance, attach one lead of the tester to the red-black wire of the
2-pin ignition coil connector and the other lead to the spark plug cap. The secondary coil
resistance should be between 16.5-19.0kΩ (shown above).
6. Replace the ignition coil if the resistance is outside of the range shown below.
Fig. 20
Fig. 19
2-Pin Connector
Blue-White Wire
Red-Black Wire Wire
Spark Plug Cap
Ignition Coil
Ignition Coil Connector
30 PH2400PRi/E SM, Rev. 2019-02-13

4.5.3 Ignition Switch Inspection
▪ Before beginning to test the ignition switch, make sure the battery is fully
charged and the terminal connections are clean and tight (section 3.2).
1. Remove the 6 control panel screws 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 in (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. Fig. 21
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) 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 12V (Batt+) 12V (Batt+) 12V (Batt+)
Orange 0V 12V (Batt+) 12V (Batt+)
Blue 0V 0V 12V (Batt+)
Pink 0V (Gnd) 0V 0V
31 PH2400PRi/E SM, Rev. 2019-02-13

4.6 Oil Level Sensor Fails to Stop Engine with Low Oil
Completely drain oil, disconnect the oil

level sensor wire and check the
No continuity Check and repair all wire connections as
continuity between sensor wire and
instructed. Replace the oil level sensor if
chassis ground. See section 4.6.1 for
necessary (section 4.6.1).
details.
Continuity
Ground the pink wire from the ECU & No light

digital display to engine block (section Replace the digital display.
4.6.1). Does the low oil light illuminate?
Light comes on
Check for spark with the pink wire Spark

Replace the ECU.
grounded (section 4.6.1).
No spark
ECU is OK.
32 PH2400PRi/E SM, Rev. 2019-02-13

4.6.1 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 on the bottom of the
crankcase of the engine. If the oil sensor needs replaced, the outer case will need removed to
allow access (refer to section 5.3).
1. Remove the maintenance door and locate the oil sensor lead which has yellow connectors
and is located near the dipstick (Fig. 22).
2. Disconnect the low oil sensor while the engine is running (Fig. 23).
3. The yellow male connector that goes to the LCD display module has a pink wire and a
yellow-green wire. Connect the pink and yellow-green wires together with a jumper wire. The
engine should die and the low oil light should come on. 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 black
wire and the yellow/green wire of the oil sensor yellow female connector (Fig. 23). No
continuity indicates a normal condition. If there is any continuity at all, replace the oil sensor.
5. Continuity (0.1-1.0Ω) 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 on oil.
Yellow Connector
Yellow Connector to to the Low Oil
the Module Sensor
Fig. 23
Fig. 22
Low Oil Sensor

Lead
Check Continuity
between the two
wires from the low
oil sensor
33 PH2400PRi/E SM, Rev. 2019-02-13

4.7 Engine Stops Running
Refer to section 4.2. Restore starter

No
Does starter crank? operation and return to this flow chart if
Starter cranks the generator now cranks but won’t start.
Low fuel
Check fuel level. Add fuel and restart the engine.
Sufficient fuel
Check the fuel filter and fuel lines for Blocked Replace fuel filter or lines. See section
blockage. See section 3.9. 3.9.
Not blocked
Low oil Fill oil reservoir to the proper level and
Check the oil level.
restart the engine.
Sufficient oil

Replace fuse. Restart engine.
battery power wire.
Fuse good
Codes found Refer to section 5.1.3 for code
Check fault codes. See section 5.1.3. descriptions. Go to appropriate section
Remove and inspect the spark plug for a Worn or

fouled plug Clean or replace spark plug and perform
worn, wet or fouled electrode. See any service recommended based on plug
section 3.6 for details. deposits.
Good spark plug
Weak spark
or no spark Refer to ignition troubleshooting section
Check for spark. See section 4.5.1. 4.5. Perform necessary tests and repairs.
Good spark
Faulty fuel
pump
Normal
Faulty fuel
injector
Check fuel injector. See sections 5.1.9 Clean or replace fuel injector as required.
Normal
Abnormal Replace MAP sensor or repair as

detailed in section 5.1.4.
Normal
If the generator will start, but bogs or dies Abnormal Replace the step motor and restart the
when loaded, inspect the step motor. engine. See section 5.1.11.1.
See section 5.1.11.2.
Normal 1. Check the valve clearance (section 3.6).
2. Check for carbon deposits on the valves &
Perform compression test as detailed in Abnormal combustion chamber. Clean as
section 4.4. necessary.
5.13). Lap valves, or replace & regrind as
necessary.
34 PH2400PRi/E SM, Rev. 2019-02-13

4.8 Engine Speed Cannot Increase or is Hunting
Check the fuel filter and fuel lines for Restricted Replace fuel filter or lines. See section
restrictions. See section 3.9. 3.9.
Clean
Check the air filter element for dirt & Dirty Clean the air filter element. See section
restrictions. See section 3.5. 3.5.
Clean
Inspect spark arrestor for carbon build Dirty Remove and clean carbon deposits. See
up. See section 3.10. section 3.10.
Clean
Codes found
Worn or Clean or replace spark plug and perform

Remove and inspect the spark plug for a fouled plug
worn, wet or fouled electrode. See any service recommended based on plug
section 3.6 for details. deposits.
Good spark plug
Leaking Replace vacuum lines and/or intake

Check the intake manifold gaskets and
manifold gaskets as required. See
vacuum lines for leakage.
section 5.1.11.
Normal
Abnormal Do output test. Replace MAP sensor or

repair as detailed in section 5.1.4.
Normal
Faulty fuel
pump
Normal
Check the throttle control step motor. See Abnormal Replace step motor. See section
section 5.1.11.2. 5.1.11.1.
Normal Faulty fuel
injector
Check fuel injector. See section 5.1.9. Clean or replace fuel injector as required.
Normal
Inspect O2 sensor. See section 5.1.5. Abnormal Do output test. Replace O2 sensor if
necessary. See section 5.1.5.
Normal
Inspect the intake manifold and the

throttle plate and step motor. See Abnormal Replace or repair as required. See
sections 5.1.11 and 5.1.12. sections 5.1.11 and 5.1.12.
Normal
1. Check the valve clearance (section 3.6).
Perform compression test as detailed in 2. Check for carbon deposits on the valves &
Abnormal
section 4.4. combustion chamber. Clean as
necessary.
5.13). Lap valves, or replace & regrind as
necessary.
35 PH2400PRi/E SM, Rev. 2019-02-13

4.9 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 detects 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 begin revving at or close to its top speed. This will activate the engine overspeed
protection and each of the following four symptoms will be present.
▪ The ECU will draw the engine down to idling speed.
▪ The digital display will indicate zero (0) Volts.
▪ The 120 V receptacles will not supply voltage, regardless of breaker settings.
▪ The inverter cannot be re-activated be pushing the overload reset button or restarting the
engine.
In this case verify inverter failure (section 4.10) and replace inverter (section 5.10).

Codes found
Leaking Replace vacuum lines and/or intake

Check the intake manifold gaskets and
manifold gaskets as required. See
vacuum lines for leakage.
section 5.1.10.
Normal
Inspect the intake manifold and the

throttle plate and step motor. Inspect Abnormal Replace or repair as required. See
throttle plate for obstructions. See sections 5.1.10 and 5.1.11.
sections 5.1.10 and 5.1.11.
Normal
Refer to wiring diagram (section 1.3).
Inspect the wire carrying the loading Abnormal
Repair an open or short in the load signal
signal from the inverter to the ECU. wire.
Normal
Inspect all wires between the inverter, Abnormal

step motor, and the ECU for breaks or Repair the wire harness as necessary.
shorts.
Normal
Replace the ECU.
36 PH2400PRi/E SM, Rev. 2019-02-13

4.10 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 reset button
on the control panel. The unit must be shut down with the key and restarted to
restore AC power output.
Does digital display indicate overload? (It Disconnect the load and press the
Yes
will show “OVER” in the power field and overload reset button. If the inverter fails
display 000.0V and 00.0A) to reset, shut down generator and restart.
No
Check all circuit breakers. Are any of Tripped

them tripped? Disconnect the load and reset breakers.
Not tripped
Stop the engine and check the AC

Abnormal
receptacles for burnt out contacts and Replace the AC receptacles if necessary.
loose or burnt connections.
Normal
Check to see if the engine feels jammed Engine

or seized upon being shut down. There jammed Inspect the rotor magnets for damage,
could be magnets that have broken free replace the rotor if damaged. See section
from the rotor. Inspect the rotor. See 5.9.
section 5.9.
Engine turns normally
Measure the stator output voltage while Abnormal Inspect and repair stator wire harness or
running (see section 4.11), and the stator
replace stator. See section 5.9.2.
winding resistance (see section 5.9.1).
Normal
Replace inverter. See section 5.10.
37 PH2400PRi/E SM, Rev. 2019-02-13

4.11 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. Follow steps 2-10 in (section 5.3) to remove the outer case and gain access to the stator
connections.
2. Disconnect the 4-pin step motor connector located near the air cleaner.
3. Find and unplug the 6-pin stator connector from the inverter and start the engine (Fig. 23). It will
be necessary to manually adjust the throttle to make the engine run in the upper RPM range
(about 3500-4000rpm) 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. 24). There
should be approximately 180-300VAC 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 assembly. 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 assembly 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 5.10.2).
Fig. 23
6-Pin Stator
Connector
Fig. 24 6-Pin Stator

Connector
6 4
White Sub
Windings
3&6
3 2 1
Black Phase Wires

1, 2 & 4
38 PH2400PRi/E SM, Rev. 2019-02-13

4.12 No DC Output at Battery Charge Receptacle.
Abnormal Reset DC circuit breaker if tripped. Check

Check the DC circuit breaker. continuity through breaker, replace if
Normal faulty.

Replace fuse.
battery power wire.
Fuse is good
Inspect wires of the 3-pin connector from

Find the 3-pin connector from the voltage the voltage regulator for breaks and
regulator (section 4.14). With the Abnormal shorts (section 4.14, Fig. 27). Check
generator running, verify that there is 13- continuity through to the DC receptacle.
15V on the red-black wire (section 4.14, Repair as necessary. If there are no
Fig. 27). wiring issues, replace voltage regulator.
4.13 Battery Will Not Charge

Charge the battery using the
Before troubleshooting, inspect battery recommended charger (section 3.2).
condition (section 3.2). Inspect the Abnormal Perform a load test to make sure the
battery terminal & quick disconnect battery maintains adequate voltage under
connections. load. Clean battery terminals. Replace
battery if necessary.
Normal
Check the DC voltage at the battery and Check all wire connections of the voltage
Abnormal
the control panel with the generator regulator. Test the voltage regulator
running. See steps 3 and 4 on the (section 4.14).
following page.
Normal
With the generator running, unplug the Check the wiring harness for breaks or
stator low voltage winding from the Abnormal shorts, repair as necessary. If no wiring
voltage regulator. Measure the voltage issues found, replace the stator (section
between the blue wires (Fig. 25). 5.9).
Voltage: 16-20VAC
Normal
Replace the voltage regulator.
Fig. 25 Low Voltage

Windings
from Stator
To the
Voltage
Regulator
39 PH2400PRi/E SM, Rev. 2019-02-13

4.14 Voltage Regulator Testing
1. To access the voltage regulator, follow steps 2-10 in section 5.3.

2. To access the 2-pin stator connector, remove the voltage regulator bolt and pull it off the
chassis. Use a jumper wire to ground the body of the voltage regulator while conducting the
test. After conducting the voltage regulator tests, re-assemble using the steps in the reverse
order.
3. With the generator running, unplug the stator low voltage winding from the voltage regulator.
Measure the voltage between the blue wires (Fig. 26). 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).
4. With the generator running and all voltage regulator connections connected, perform the
following steps:
a. Measure the battery charging voltage from the voltage regulator 6-pin connector (Fig.
27). Put the voltmeter positive test lead on the red wire, and the negative test lead on the
yellow/green wire. The voltage should be 12.0-14.5 VDC, depending on the condition of
the 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 3-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 13-15 VDC. If the voltage does not fall
within this range, replace the voltage regulator.
6-pin Connector 2-pin to Stator

Fig. 26 Low Voltage
Windings Fig. 27
from Stator
To the
Voltage
Regulator 3-pin Connector to Battery
and DC Receptacle
40 PH2400PRi/E SM, Rev. 2019-02-13

4.15 Engine Will Start Then Shut Down
Check engine oil level. Sometimes the

Low oil light oil level can be just above the critical
Check the low oil light. shutoff level before starting, then drop
below the shutoff level once started
No low oil light due to oil splash. Add oil if necessary.

Codes Found
descriptions. Go to appropriate
Check fault codes. See section 5.1.3.
section for testing based on code
description.
4.16 Engine Will Not Start or Stop with Remote
▪ The remote start system will not work unless the remote switch is in the ON
position. Make sure the remote switch is in the ON position before attempting a
remote start.
Does the red indicator light on the remote No Replace the remote fob battery. Replace
fob come on, when either the start or the remote fob and receiver if this does
stop buttons are pushed? not restore normal remote fob operation.
Yes
Inspect the remote switch and wires and Abnormal

connections from the remote switch Repair wiring or replace rocker switch as
located on the control panel (section 5.2) necessary.
Normal
Check 6-pin connection at the remote

receiver for dirty or damaged connections, Abnormal Repair or replace faulty connections.
and broken or shorted wires. The remote
Repair any broken or shorted wires.
receiver is attached to the end of the
battery box, behind the control panel.
Normal
Replace the remote transmitters and

receiver.
▪ The remote transmitter and receiver are a matched set and can only be
purchased in pairs.
41 PH2400PRi/E SM, Rev. 2019-02-13

.
4 17 No Output When Operating in Parallel
Before testing parallel connections, read the following important notes and cautions.
For parallel operating instructions, refer to the Parallel Mode Operation section of the
POWERHOUSE® PH2400PRi/E Owner’s Manual. A description of parallel operating procedure
follows.
▪ Turn “OFF” both generators and disconnect the parallel kit and all the electrical
devices from the generators before beginning diagnnostics.
▪ The information and instructions in this section only pertain to the parallel
operation of two POWERHOUSE® PH2400PRi/E generators.
▪ This parallel kit cannot be used for paralleling three or more generators, running
two different brands of generators, or for running different models of
POWERHOUSE® generators with the PH2400PRi/E.
4.17.1 Parallel Operating Procedure and Overload Reset
1. Prepare two POWERHOUSE® PH2400PRi/E generators for operation.

2. Connect one of the 3-pin parallel power cables from the parallel kit into each generator (Fig.
28).
3. Start both generators normally and confirm that each generator is displaying proper voltage
output on its digital display. The light on the front panel of the parallel kit should also
illuminate green steadily, and proper voltage should be indicated on the display of the
parallel kit as well.
4. Securely plug an electrical appliance into either, or both, of the parallel receptacles (Fig. 29)
and switch on the electrical appliance.
▪ Use only the parallel kit outlets during parallel operation of two generators. Do
not also plug appliances into the AC outlets on the generator control panels.
▪ The required power for the electrical appliances cannot exceed the combined
power output of the parallel generators The maximum load is equal to or greater
than 4400W (rated output: 4300W).
▪ Don't disconnect the parallel output cable during parallel operation. Doing
so will cause permanent damage not covered under warranty.
Fig. 28
Two PH2400PRi-E’s Connected in Parallel
42 PH2400PRi/E SM, Rev. 2019-02-13

Fig. 29 Parallel Kit Front Panel
20 and 30
Amp Circuit
Breakers
120V-30 Amp
Locking Receptacle
(L5-30)
Output Indicator
(Green)
Grounding
Terminal
120V-20 Amp
Receptacle
Fig. 30 Parallel Kit Display

Voltage Amperage
Hertz Wattage
Elapsed Time
in Parallel
▪ To prevent electrical shock from faulty appliances, the parallel kit should be
grounded. Connect a length of heavy cable between the parallel ground
terminal and an external ground source.
5. During normal parallel operating conditions, both generators display their individual voltage,
amperage, and wattage output on their digital displays. The light on the front panel of the parallel
kit illuminates green steadily. The combined power output information will be displayed on top of
the parallel kit as well (Fig. 30).
6. If the generators are overloaded, both generators will display “OVER” in the wattage field of their
digital displays. The output indicator light and digital display of the parallel kit will also be off.
7. At this time, there will be no electrical output from the parallel panel and the connected appliance
or load will be shut off.
8. Remove all electrical loads from the generators and/or parallel kit and then determine and
correct the cause of the overload.
9. To reset the overload condition (OVER), press and release the overload reset button (green) on
the control panel of the both generators. Within 15 seconds, the generators digital displays
should indicate normal voltage, amperage, and wattage readings.
43 PH2400PRi/E SM, Rev. 2019-02-13

4.17.2 Troubleshooting Parallel Operation
Follow the flowchart below to diagnose issues with parallel operation.
Disconnect parallel kit. Check whether Abnormal

Perform single generator
the two generators work well
troubleshooting (section 4.10).
separately.
Normal
Verify that the no load voltage output is Voltages

need adjusted Follow the inverter preparation and
121.5V ± 0.7V on both generators
adjustment procedures detailed in
using a calibrated voltmeter, when
section 5.2. Return to the flowchart.
being operated separately.
Voltages good
Connect parallel kit, start generators, Yes

and add loads. Is parallel power Exit troubleshooting flow chart.
restored?
No Inspect parallel kit breakers,
connections, receptacles, and
Are either one, or both, of the No display. If resetting breakers, or
generators indicating “OVER” in the restoring or repairing connections,
wattage field of the digital display? does not restore parallel power
output and display illumination, then
Yes
replace the parallel kit.
Disconnect all loads and reset both Won’t reset
Shutdown and restart generators
inverters. and attempt to reset inverters again.
Normal If it still won’t reset, test and replace
inverter/inverters as required
Power restored. Reconnect loads (sections 4.10 and 5.10).
individually, to see which one of the
applied loads is causing a short or
overload.
44 PH2400PRi/E SM, Rev. 2019-02-13

5. REPAIR
5.1 Electronic Fuel Injection (EFI)
This generator is equipped with an Electronic Fuel Injection (EFI) system. An on-board computer,
referred to in this manual as an ECU (Engine Control Unit) utilizes a series of virtual maps (lookup
tables) that provide values for various aspects of engine performance. The ECU analyzes data
provided through the various engine sensors to determine the best combination of values from these
lookup tables to provide optimum performance and minimize emissions. This is communicated to the
generator components through the use of digital signals. This is in contrast to non-computer
controlled ignition systems that rely on mechanical feedback, and sometimes vacuum, to control the
motion of the various components.
5.1.1 Overview of EFI System
The ECU collects and processes data from a group of sensors that monitor various engine and
inverter conditions. It uses that information to meter the fuel, adjust the ignition timing and control
the throttle of the engine. Fault codes are generated by the ECU whenever it detects a
malfunction of an EFI system sensor or component. The components of the EFI system are
shown below (Fig. 31). Their functions, maintenance and service are detailed in the sections that
follow.
Fig. 31 Temperature O2 Sensor

Sensor
Throttle Body/Intake Manifold Crankshaft
Position
Sensor
Fuel Injector
Ignition Coil
Step Motor MAP Sensor
ECU
45 PH2400PRi/E SM, Rev. 2019-02-13

5.1.2 Engine Control Unit (ECU)
The ECU is the computer that controls the EFI system. It has on-board diagnostics that will store
and display fault codes if it detects problems with the other components of the EFI system. The
fault codes will be discussed in section 5.3.1 to follow. The ECU is solid state and very reliable, it
is only replaced after all other diagnostic possibilities have been eliminated. All the other sensors
and EFI components and the wires from the ECU to each of the EFI components should be
checked first, for shorts or high resistances before concluding the ECU is at fault. Refer to the
wiring diagram in section 1.3 when verifying the status of these wires. The ECU connector pinout
is shown in the upper left corner of the wiring diagram.
Removal and installation of ECU
1. Remove the spark plug access cover. The ECU can be seen, held in slide mounts against
the backside of the fuel tank (Fig. 32).
2. Slide the ECU out of its mounts in the direction of the red arrow (Fig. 25).
3. Maneuver the ECU out of the spark plug access hole.
4. Disconnect the 2-pin and 18-pin connectors and remove the ECU.
5. Install in reverse order of removal.
Fig. 32
46 PH2400PRi/E SM, Rev. 2019-02-13

5.1.3 Fault Codes
5.1.3.1 Reading Fault Codes
The fault codes are read using the digital display on the control panel (see Fig. 33 below). If
the ECU has stored fault codes the Low Oil Indicator (see Fig. 34 below) will blink steadily
whenever the key is in the on position. If the generator is truly low on oil, this light will
illuminate steadily, but not blink.
It should be noted that if a fault condition is suspected but the Low Oil Indicator is not
illuminated, go ahead and follow the procedure for reading the fault codes. Fault code 0650
might be present which indicates that there is a problem with the Low Oil Indicator itself. The
Low Oil Indicator is an integral part of the digital display and the entire digital display will
need to be replaced to fix the problem.
1. If the Low Oil Indicator blinks repeatedly, press the Fault Code Reset Button on the top
right of the digital display (Fig. 34).
2. The display will cycle through the fault codes in the Wattage (P) data field of the digital
display. Record all the fault codes.
3. Conduct the diagnostic procedures suggested for each fault code and any repairs
necessary.
4. Erase the fault codes and restart the unit to see if they reappear and if further diagnosis
or repair is needed. Fault codes are erased by holding the Fault Code Reset Button
down for 10 seconds or more while the key is in the on position. The key must then be
turned off to complete the process.
Fig. 34
Fault Code
Reset Button
Data Fields
Fig. 33
Low Oil Indicator (red) /

Fault Code Indicator
Sample Fault Code
47 PH2400PRi/E SM, Rev. 2019-02-13

5.1.3.2 Fault Code Definition and Descriptions
When the generator is running the ECU is constantly monitoring sensors and sending
signals to the different components of the EFI system. When it detects a problem with one of
these devices it stores a fault code in its memory that can be retrieved for diagnostic
purposes. It uses standard OBD II codes and they are shown in the following table along
with the descriptions of the conditions producing the code. If a fault code is produced inspect
for the condition described below and inspect the respective sensor as described in that
sensor’s subsection. Retrieving the fault codes is discussed in section 5.1.3.1.
OBD II
EFI System Description of Condition Producing
Fault Code OBD II Fault Description
Device the Fault
(DTC)
P0261 Cylinder 1 Injector Circuit Low Signal line short to ground
Fuel Injector Signal line short to battery voltage
P0262 Cylinder 1 Injector Circuit High
Signal line break
Signal line short to ground
P0107 MAP Circuit Low Input
Signal line break
MAP Sensor
Signal line short to battery voltage
P0108 MAP Circuit High Input
Ground line break
P0130 O2 Sensor Circuit Malfunction Signal line break
O2 Sensor P0131 O2 Sensor Circuit Low Voltage Signal line short to ground
P0132 O2 Sensor Circuit High Voltage Signal line short to battery voltage
Engine Coolant Temperature
Engine P0117 Signal line short to ground
Circuit Low Input
Temperature
Sensor Engine Coolant Temperature Signal line short to battery voltage
P0118
Circuit High Input Signal line break
Idle Control System
Step Motor P0505 Signal line short to ground
Malfunction
Signal line break
Malfunction
P0650 MIL Control Circuit Malfunction Signal line short to ground
Indicator Light
Signal line break
48 PH2400PRi/E SM, Rev. 2019-02-13

5.1.4 Manifold Air Pressure Sensor (MAP) Fig. 35
The MAP sensor (Fig. 35) is a pressure transducer that
translates the current manifold air pressure into a voltage
signal to the ECU. It is installed on a vacuum line coming from
the intake manifold (section 5.1.4.2). The pinout for the MAP
sensor connector is shown in the table below.
MAP Sensor Pinout
Green 0-5VDC signal to ECU
Red 5VDC input from ECU
Black Ground
The MAP sensor is one of the key sensors required by the

ECU to keep the engine running properly. If this sensor is not
working the engine will either die, when loads are put on it, or not
run at all. If the ECU has produced the fault codes 0107 or 0108, or you
have reason to suspect the MAP sensor is malfunctioning, perform the
test detailed below. Before beginning the test, make sure the generator
battery is fully charged. Also, inspect the MAP sensor vacuum line for
restrictions, leaks, and deterioration; replace if necessary.
5.1.4.1 MAP Voltage Output Test
1. Remove the maintenance door. The white 3-pin MAP sensor
connector will be bundled together with other connectors near the
air cleaner.
2. Remove the vacuum line from the end of the MAP sensor and connect it
to a hand operated vacuum pump equipped with a pressure gauge
similar to the one shown.
3. Turn the ignition key to the on position.
4. Check the input voltage. Locate the 3 wire MAP sensor connector, but
do not disconnect it. Test the voltage between the black and red MAP
sensor wires. It should be 4.9-5.1VDC. If it is not in this range inspect
the wire harness back to the ECU for breaks or shorts. If no wiring
fault is found, verify the MAP input voltage at the ECU. If the MAP
sensor input voltage is not 4.9-5.1VDC at the ECU then the ECU is at
fault and needs to be replaced.
5. Check the signal voltage (MAP sensor still connected to harness, key is still on). Check
the voltage between the black and green MAP sensor wires. At atmospheric pressure the
voltage should be approximately 4.0-4.1V, and will vary with barometric pressure and
altitude. Slowly pump the vacuum pump connected to the MAP sensor in step 2. The
voltage should fall gradually. The voltage vs. pressure graph is shown below. Pressure is
shown in kPa (kilopascals), and conversions to psi and in-Hg are given for reference.
When the gauge on the vacuum pump shows 10in-Hg, it should read about 2.5VDC, at
20in-Hg it should read about 1VDC. If it is reading no voltage, or the voltage fails to
change, or it is getting readings that are grossly off, then the MAP sensor needs to be
replaced.
Atmospheric Pressure = 101.3kPa, 14.7psi,

or 0.0 in-Hg vacuum
1 psi = 6.9kPa
1 in-Hg = 3.4kPa
49 PH2400PRi/E SM, Rev. 2019-02-13

5.1.4.2 Replacing the MAP Sensor

2. Find the white 3-pin MAP sensor connector bundled together with other connectors near
the air cleaner (Fig. 36).
3. Remove the MAP sensor connector from the bundle and disconnect it.
4. The end of MAP sensor is installed on a vacuum line coming from a port on top of the
intake manifold. It can be seen above the air cleaner (Fig. 36).
5. Remove the air cleaner cover and remove the two intake manifold stud nuts (circled in
Fig. 37).
6. Remove the air cleaner and disconnect the MAP vacuum line from the intake manifold.
7. Install the new MAP sensor using steps 1-6 in reverse order.
Fig. 36 MAP Fig. 37

Sensor
MAP Sensor
Connector
50 PH2400PRi/E SM, Rev. 2019-02-13

5.1.5 Oxygen Sensor (O2)
The O2 sensor (Fig. 38) sends a voltage signal to the ECU that varies
with the amount of O2 in the engine exhaust. The ECU uses this signal to
check that the correct amount of fuel is being metered through the fuel
injector to maintain the best fuel/air ratio for maximizing the performance
and minimizing the emissions. The ECU uses the other sensors to
determine how much fuel to provide and the O2 sensor is providing
feedback to the ECU on whether or not the fuel mixture is correct. This is
the normal mode of operation and it is called running in a “closed loop”. If
the O2 sensor is not working or the signal is not reaching the ECU, the
ECU will continue to run the engine based on input from the other
sensors and data stored in lookup tables, but it will have no feedback Fig. 38
from the O2 sensor. It will have no way to verify that the fuel mixture is
correct; this is called running in an “open loop”. If the ECU is running in continuous “open loop” it
will generate one or more of the following fault codes: 0130, 0131 or 0132. In this case, the
cause of the faulty signal or lack of signal from the O2 sensor will need to be determined. The
following information and testing procedure will help determine if a new O2 sensor is needed.
The voltage signal varies from 0.1-1.0VDC as the ratio of the percentage of O2 between the
ambient air and exhaust air changes. As the percentage of O2 in the exhaust air approaches
zero (the fuel mixture gets richer) the voltage signal approaches 1.0VDC. When the percentage
of O2 in the exhaust air gets closer to ambient air (the fuel mixture gets leaner) the voltage signal
drops closer to 0.1VDC. The procedures for testing the O2 sensor are detailed below.
It should also be noted that during periods of changing loads, or when the generator is running at
maximum capacity, the ECU is not using the O2 sensor signal to run the engine. If the engine
has poor performance under these conditions, then the cause is probably not the O2 sensor. The
ECU uses the O2 sensor signal to determine how much it can safely lean out the fuel mixture
while the generator is under stable loads in the 800-2200W load range. If the engine has poor or
unstable performance under these conditions, then the O2 sensor is among the probable causes.
5.1.5.1 O2 Sensor Testing
▪ Do not run the unit for more than 5 minutes at a time with the outer case
removed while doing diagnostic testing. The inverter will overheat due to
insufficient cooling and could fail or sustain permanent damage as a result.
1. Follow steps 1-10 in section 5.3 to remove the outer case. The O2 sensor lead will be
coming out of the intake fan cover above the starter. It has one blue 2-pin connector
(output to ECU) and one red 2-pin connector (heater power).
2. If any O2 sensor fault codes 0130, 0131 or 0132 are present then check for wiring faults
before checking the O2 sensor voltage output. Verify continuity from the yellow-green
wire of the O2 sensor to pin 1 of the ECU (section 5.1.2 for ECU location, section 1.3 for
ECU pinout). Verify that there are no shorts and that the yellow-green wire is grounded at
the O2 sensor and that pin 1 of the ECU also has good ground. Verify that the grey wire
of the O2 sensor has continuity to pin 5 of the ECU and that there are no shorts to ground
or battery voltage. Fix any wire issues found before proceeding to output test.
3. Check the O2 sensor heater. Disconnect the red 2-pin connector. With the engine
running, verify that the yellow-red wire is at 13-15V, if not check the voltage regulator
(section 4.13). Verify the yellow-green wire is grounded at pin 1 of the ECU. Measure the
resistance between the 2 black wires coming from the O2 sensor. The resistance should
be between 5-10Ω. If the resistance is not within range, replace the O2 sensor. Using
jumper wires connect one O2 sensor black wire to the positive battery terminal, and the
other black wire to the negative battery terminal, while touching the body of the O2
sensor body. Verify that it warms up within 2-3 minutes. If not, replace the O2 sensor.
4. Before testing the O2 sensor output make sure the engine has been running for 3-5
minutes to bring the O2 sensor up to operating temperature. Be aware that a faulty O2
51 PH2400PRi/E SM, Rev. 2019-02-13

sensor will not prevent the generator from starting and running; if the generator will not
start and run, there are other problems present.
5. With the O2 sensor disconnected and the generator running with no load (or less than
500W) measure the voltage between the wires of the blue 2-pin connector of the O2
sensor. The voltage should fluctuate in the range of 0.1-1.0VDC.
6. Increase the load on the generator to 2000-2300W while continuing to read the O2
sensor voltage. The voltage should become steadier and fall in the range of 0.6-0.9VDC.
If no voltage is read or the readings are not within the ranges specified in steps 4 and 5,
replace the O2 sensor (see section 5.1.5.2).
7. If the O2 sensor passed the output test, reconnect it and clear the ECU of any fault codes
that may have been generated during the test (refer to section 5.1.3).
5.1.5.2 Replacing the O2 Sensor

1. Follow steps 1-10 in section 5.11 to gain access to the O2 sensor (Fig. 39).
2. Remove the O2 sensor using a 14mm open end wrench. Use of a penetrating oil and/or
heating the exhaust manifold, may be necessary to loosen an O2 sensor that has been in
place for a long period of time and/or many hours of operation.
3. Before installing the new O2 sensor, apply a modest amount of a copper based anti-seize
lubricant to the threads (Permatex 09128 or equivalent). This can be purchased at most
major automotive parts suppliers.
4. Install the new O2 sensor in the exhaust manifold. Torque to 18-20 Nm (13-15 ft-lb), or
tighten ⅛-¼ turn after seating washer.
5. Install the items removed in reverse order of removal.
Fig. 39
52 PH2400PRi/E SM, Rev. 2019-02-13

5.1.6 Temperature Sensor
The temperature sensor (Fig. 40) is a thermistor, which is a device whose resistance changes
with temperature. The ECU reads this varying resistance to determine the temperature of the
engine. The temperature sensor is mounted under the head of one of the valve cover bolts (Fig.
41). Its connector can be accessed inside the maintenance door. If the ECU gets a signal that is
out of range from the temperature sensor it will generate fault code 0117 or 0118. If this occurs,
use the following test to determine if the temperature sensor is working properly.
5.1.6.1 Temperature Sensor Test / Replacement
1. Remove the maintenance door. The white 2-pin Fig. 40

temperature sensor connector is located below the
air cleaner. Disconnect the temperature sensor.
2. Inspect the two wires coming from the temperature
sensor for shorts. Repair if necessary.
3. Verify that the yellow/green wire from the connector
attaching to the temperature sensor has continuity
to pin 1 of the ECU (refer to section 5.1.2 and the
wiring diagram in section 1.3) and to chassis
ground. Repair if necessary.
4. Verify that the purple wire from the connector
attaching to the temperature sensor has continuity
to pin 6 of the ECU and there are no shorts to
ground or battery voltage. Repair if necessary.
5. Follow steps 1-8 in section 5.11 to gain access to
the temperature sensor. Fig. 41
6. Remove the temperature sensor from the generator
(Fig. 41).
7. Measure the resistance between the two wires of
the temperature sensor. At typical room
temperatures 68-77°F (20-25°C) it should measure
between 48.0-67.3kΩ. Immerse the sensor eyelet in
rapidly boiling water (212°F or 100°C) while still
measuring the resistance between the wires at the
other end. The resistance should begin to fall
steadily. Wait about a minute for the resistance to
stabilize and note the reading. It should be 3218-
3383Ω. If the resistance is not in the specified
range or does not change with changing
temperatures, replace the temperature sensor.
8. Re-install the temperature sensor making sure to clean all contact surfaces between the
mounting bolt and the cylinder head for good heat transfer. Re-assemble the generator
by following steps 1-8 in section 5.11 in reverse order.
Temperature Sensor
Dimensions in mm
53 PH2400PRi/E SM, Rev. 2019-02-13

5.1.7 Crankshaft Position Sensor (CPS)
The Crankshaft Position Sensor (CPS) (Fig. 42) is an inductive pick-up that sends a signal to the
ECU every time the engine goes by top dead center (TDC). It is mounted above the rotor as
shown in Fig. 43. The ECU uses this sensor to time the ignition spark and the firing of the fuel
injector. If a CPS malfunction is suspected, follow the procedures for checking the coil resistance
and setting the air gap (see air gap setting procedures when replacing the CPS).
5.1.7.1 Checking CPS Coil Resistance

Fig. 42
1. Follow steps 1-10 in section 5.3 to remove the outer case.
Locate the 2-pin green CPS connector coming out of the intake
fan cover, above the starter. Disconnect the green 2-pin CPS
connector (Fig. 42).
2. Check for continuity between both CPS wires and ground, there
should be no continuity. If there is replace the CPS.
3. With cold engine, measure the resistance between the blue-
white and green-white wires of the CPS connector to determine
the coil resistance. Replace the CPS if it is out of the range
shown below.
CPS coil resistance (cold) 113-130Ω
5.1.7.2 Adjusting the Air Gap of the CPS

1. Follow steps 1-7 in section 5.8 to remove the intake fan cover.
2. Check the clearance between the CPS and the TDC block of the rotor by inserting a
feeler blade (0.040”-0.050”) between them (see Fig. 43). If the gap is correct there
should be only slight resistance felt when sliding the feeler blade in between them. Adjust
if necessary (step 3).
3. Loosen the CPS bolts (circled in Fig. 43) and insert the feeler gauge. Allow the magnetic
tip of the CPS to contact the feeler blade 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 rotor components.
5. Re-assemble in the reverse order of disassembly.
CPS sensor clearance 1.0-1.2mm (0.040”-0.050”)
Fig. 43
CPS
TDC
Block
Rotor
Feeler
Gauge
54 PH2400PRi/E SM, Rev. 2019-02-13

5.1.8 Fuel Injector
The fuel injector (Fig. 44) is a mechanical device that delivers the fuel to the engine Fig. 44
and is controlled by a signal from the ECU. It is mounted on top of the intake manifold
and can be accessed through the maintenance door. It has a 2-pin connector that is
held on the injector with a spring clip. The connector has a red-white and a black-white
wire. The red-white wire receives battery voltage whenever the ignition key is in the
ON position. The black-white wire is the signal wire from the ECU. The ECU will
produce fault codes 0261 or 0262 if it senses a problem with the fuel injector. If these
fault codes are present or the fuel injector is suspected of malfunction perform the
following test. Make sure the battery is fully charged and the battery post connections
are clean and tight before beginning the test.
▪ Wait 5-10 seconds after engine shutdown prior to removing fuel line to allow the
fuel pressure to bleed off.
5.1.8.1 Fuel Injector Test / Replacement
1. Make sure you have verified that the fuel pump (section 5.1.10) Fig. 45
and CPS (section 5.1.7) are working before beginning this test.
2. Follow steps 2-9 in section 5.1.11.1 to remove the intake manifold.
3. Remove the spring clip from the 2-pin connector on the side of the
fuel injector and disconnect it.
4. Turn the ignition key to the ON position and check the battery Injector
voltage. Check the voltage at the red-white wire of the 2-pin Bushing
connector. It should be the same as the battery voltage within
0.5V. If not, then check the red-white wire for continuity, dirty
connections or shorts. Repair as necessary.
5. Remove the spark plug access door to access the ECU (section Injector
5.1.2). Disconnect the 18-pin connector. Inspect the resistance Bolt
between the black-white wire at the 2-pin connector and the black-
white wire on pin 17 of the ECU shown in the wiring diagram in
section 1.3. The resistance should be zero. Make sure there are no
shorts to ground or to battery voltage. Repair as necessary.
Reconnect the ECU.
6. Next remove the fuel injector in preparation to do a physical test.
Remove the fuel injector bolt and bushing shown in Fig. 45. Gently
pull the injector out. Remove the hose clamp and fuel hose from the injector cap,
remember to wait 5-10 seconds after the ignition key has been turned off.
7. Remove the injector cap and inspect the cap and top of the injector (Fig. 46 and 47).
Clean out any obstructions or debris using compressed air. Apply a thin film of motor oil
or assembly lube on the upper fuel injector O-ring and reinstall the injector cap.
Fig. 46 Fig. 47
55 PH2400PRi/E SM, Rev. 2019-02-13

8. If you have a fuel injector tester as shown (Fig. 48), then test the injector per tester
instructions and verify its proper operation or replace it if necessary. If you don’t have a
fuel injection tester then pull the fuel line and fuel injection connector through the
maintenance door opening and connect them to the fuel injector.
Fig. 48
Fuel Injector Tester
9. Hold the end of the fuel injector over a fuel safe container and turn Fig. 49
the ignition key to the start position while watching the end of the
fuel injector. It should produce a quick spray of fuel intermittently,
timed with the cranking of the engine. The spray of fuel should look
like the one in Fig. 49, if it is a good injector. If it produces no spray,
drips, dribbles or produces an abnormal or weak spray; replace the
injector and repeat the test.
10. If you have replaced the fuel injector and you still see no spray, then
test the signal in the black wire from the ECU using a fuel injector
pulse tester as shown (Fig. 50). Test the signal per the tester
instructions and replace the ECU, if necessary. If you do not have a
fuel injector pulse tester and you have tested the fuel injector and Fig. 50
made sure there are no wiring issues, then replace the ECU.
11. Repeat the test to make sure normal fuel injector spray has been
restored. Reinstall the fuel injector, ECU, control panel and
maintenance door. Apply a thin film of motor oil or assembly lube on
the lower fuel injector O-ring before inserting it in its mounting hole.
Fuel Injector Pulse Tester
56 PH2400PRi/E SM, Rev. 2019-02-13

5.1.9 Fuel Pump/Gauge Assembly
The PH2400PRi/E is equipped with an electric fuel pump/gauge assembly mounted inside the
fuel tank next to the filler neck (Fig. 51). The fuel pump needs to maintain 25psi in the system for
proper operation of the fuel injector. If it’s suspected that the fuel pump is faulty conduct the
following test. Before beginning the test make sure the battery is fully charged and that the
connections are clean and tight.
▪ Wait 5-10 seconds after engine shutdown prior to removing fuel line to allow
the fuel pressure to bleed off.
5.1.9.1 Testing the Fuel Pump Fig. 51
1. Remove the maintenance door. Remove the fuel line from

the top of the fuel injector and connect it to a fuel pressure
testing gauge similar to the one shown in Fig. 52.
2. Turn the ignition key to the ON position while listening
closely at the top of the fuel tank near the filler neck
(remove the fuel cap if necessary). If the fuel pump is
working properly it will come on for several seconds when
the key is turned on, to bring the fuel pressure up to the
required pressure before starting. Observe the test gauge
while the pump is running and verify that the pressure
reaches 25psi. If it does, then the pump is good, and the
test is complete. If the pump fails to come on proceed to
step 3. If it comes on but does not come up to pressure
proceed to section 5.1.10.2 to remove the fuel pump.
3. Follow steps 2-10 in section 5.3 to remove the outer case
Fig. 52
and gain access to the fuel pump/gauge assembly. The
fuel pump/gauge assembly is on top of the fuel tank and Fuel Pressure
has a 3-pin white connector screwed on top of it. Identify Testing Gauge
the solid red wire (12V positive), and the yellow-green wire
(ground). Refer to Fig. 53.
4. Using two jumper wires, connect the yellow-green wire
from the fuel pump connector to the negative battery post,
and the red wire from the fuel pump to the positive battery
post (be ready to disconnect one of the jumper wires in
case of an internal short in the fuel pump). The fuel pump
should come on. Verify that the pressure reaches 25psi on
the test gauge, if so then the fuel pump is good. If the
pump fails proceed to section 5.1.10.2 to replace the
pump.
5. If the pump failed to come on in step 2, but passed step 4,
first verify that the yellow wire with the green stripe to the Fig. 53
pump is getting good ground. Repair if necessary. If the
fuel pump is getting good ground, then check to see if the
red wire is getting 12V battery voltage from pin 18 of the
ECU. Repair if necessary.
6. If there is not 12V battery voltage at pin 18 on the ECU,
then conduct a voltage regulator test (section 4.13)
7. Upon completion of a successful fuel pump test reconnect
the fuel pump connector, the fuel line on the fuel injector,
the outer case, and the maintenance door.
57 PH2400PRi/E SM, Rev. 2019-02-13

5.1.9.2 Replacing and Servicing the Fuel Pump
1. Make sure the ignition key is in the OFF position and remove the battery (section 3.2).
3. Remove the fuel cap.
4. Disconnect the green 3-pin fuel pump/gauge assembly electrical connector. Fuel Pump
Loosen the hose clamp and remove the fuel line. Tube
5. The fuel pump/gauge assembly is held in place by its rubber grommet. Gently Fig. 54
pry the fuel pump out with a broad, slotted screwdriver, working your way
around it as required. Tip the fuel pump assembly as it is lifted to avoid
knocking the fuel pump filter off the bottom of the pump or bending the fuel
level float rod as you bring it through the hole in the tank (Fig. 57).
6. If the fuel pump came on in step 2 of the fuel pump test section 5.1.10.1, but
failed to build up sufficient pressure; check the fuel pump tube for splits or
leaks (Fig. 54), and the fuel pump inlet filter for clogging (Fig. 58). Repair,
clean, or replace as necessary. If the fuel pump filter was clogged, drain and Pressure
Regulator
thoroughly flush the fuel tank before beginning reassembly. Assembly
7. Inspect the pressure regulator, housed below the fuel pump assembly outlet
(see Fig. 58). The pressure regulator assembly consists of a plunger, spring, Fig. 55
and cap (see Fig. 54). Remove the pressure regulator cap by gently prying
one of the latches off its barb on the housing (see Fig. 55). Beware that the
cap has some spring pressure on it. Remove the spring and the plunger,
using needle nose pliers on the stem of the plunger (Fig. 56). Clean any
obstructions or debris from the housing with compressed air. Inspect the
housing bore and plunger O-ring for damage, replace if necessary. Apply a
thin film of motor oil or assembly lube on the O-ring before reassembly.
Reinstall the pressure regulator assembly, and be sure the cap completely
engages the barbs. Fig. 56
8. If you have repaired the existing fuel pump, put it back in the tank and repeat
step 4 of the fuel pump test section 5.1.10.1 to verify normal operation has
been restored before continuing.
Fig. 58
Fig. 57 Pressure
Regulator
Fuel Gauge
Lever and Float
Fuel Pump
Inlet Filter
58 PH2400PRi/E SM, Rev. 2019-02-13

9. When installing the new or repaired fuel pump assembly, the assembly should be
oriented with the fuel gauge float lever parallel with the fuel tank seam (Fig 59).
10. Angle the float to insert it in the hole in the tank (Fig. 60).
11. Slide the float lever in the hole, angling the pump assembly when inserting the fuel inlet
filter (Fig. 61).
12. Straighten out the assembly and bring it into correct alignment when doing the final
lowering of the assembly into the hole in the tank (Fig. 62).
13. When installed in the correct orientation the fuel pump outlet should be pointing as
shown in Fig. 63.
14. Reinstall the outer case, the battery, and fuel cap.
Fig. 59
Align the Float
Lever with the
Tank Seam
Fig. 60 Fig. 61
Fig. 62 Fig. 63
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5.1.10 Intake Manifold
The intake manifold can be removed using the following procedure.
5.1.10.1 Intake Manifold Removal

Reference Fig. 64 for steps 3-10.
1. Remove the battery access door and disconnect the battery at the quick connector
(section 3.2).
3. Disconnect the stepper motor connector.
4. Disconnect the MAP sensor connector.
5. Disconnect the fuel line from the fuel injector, capturing any fuel that is released in the
process.
6. Remove the screw from the air filter cover and remove the air cleaner cover.
7. Disconnect the PCV hose from the top of the air cleaner.
8. Remove the two nuts from the intake manifold studs and remove the air cleaner.
9. Remove the spring clip from the 2-pin connector on the side of the fuel injector and
disconnect it.
10. Remove the intake manifold (circled in Fig. 64 below) by sliding it off its studs.
11. Re-install the intake manifold by using these steps in reverse order.
Fig. 64
Intake Manifold Studs
Fuel Injector
Intake Manifold
Air Cleaner
Air Cleaner
Cover
MAP Sensor
Intake Manifold
Nuts
Air Filter
Stepper Motor
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5.1.11 Throttle Control – Step Motor
Remove and inspect the step motor if the ECU has generated code 0505, or troubleshooting has
indicated it may be faulty. Before removing the step motor, inspect the inside of the intake
manifold to make sure there are no physical obstructions that would prevent the free motion of
the throttle plate.
5.1.11.1 Removal and Installation of Step Motor

1. Remove the intake manifold by following steps 1-10 in section 5.1.10.1.
2. Disconnect the 4-pin step motor connector.
3. Remove the two step motor screws and carefully remove the step motor (Fig. 65). Take
care not to dislodge the fork and fork spring located below the step motor bracket (Fig.
66). The spring is under compression and can be lost easily if allowed to fly off. It is not
necessary to remove the step motor bracket to change the motor. Leave the bracket on
to hold the fork and spring in place.
4. Carefully align the flat on the shaft of the replacement step motor with the flat of the fork
(indicated by arrow Fig. 66). If the step motor bracket was removed, ensure the spacer
washers are installed correctly upon reassembly.
5. Reinstall the intake manifold using the steps in section 5.1.10.1 in reverse order.
Fig. 65
Bracket Spacer Fig. 66

Washers Fork Spring
Step Motor Bracket
Step Motor
Fork
5.1.11.2 Resistance and Backlash of Step Motor

Before checking the resistance, gently 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 0.010-0.015” then replace the step motor.
1. Measure the resistance of the outlet terminals of the step motor.

Pin 1-blue - Pin 2-white：105-115Ω
Resistance value
Pin 3-red - Pin 4-black：105-115Ω
2. Replace the step motor if the resistance exceeds the standard values.
Fig. 67
3 1
4 2
61 PH2400PRi/E SM, Rev. 2019-02-13

5.2 Control Panel
5.2.1 Disassembly / Installation
1. Remove the six control panel screws (Fig. 68).

2. Details for disassembling the control panel are shown in (Fig. 69).
Fig. 68
Fig. 69
Ignition Parallel Power LCD Digital
Switch Socket Display
USB Ports
DC Battery
Charge
Receptacle
120V-20A
Circuit Ignition Key
Breaker 120V-20A
Duplex
DC Circuit
Breaker
Grounding
Stud
Remote Button
Switch Guard
Reset
Button
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5.2.2 Digital Display
This generator is equipped with an LCD digital display in the control panel (Fig. 70) that provides
continuously-updated status information for the following parameters:
▪ (U) Output Voltage

▪ (I) Output Amperage
▪ (P) Power Output (Wattage) – also Overload & Fault Code Indication
▪ (T) Run Time (hours) - Total accumulated generator run time
▪ (FUEL) Fuel level – Indicated by bars (0-5 bars)
The Low Oil/Fault Code Indicator light and the Fault Code Reset Button are also built into the
digital display. The following sections detail how to diagnose problems with the different functions
of the digital display. Before diagnosing problems with the digital display, make sure the battery
is in good condition and fully charged (see section 4.1).
Fig. 70
Fault Code
Reset Button
Data Fields
Low Oil Indicator (red) /

Fault Code Indicator
Sample Fault Code
5.2.2.1 Voltage Display Field

The voltage displayed in voltage data field of the digital display is taken directly from a
voltage signal from the inverter. If it is suspected that the voltage displayed is not correct,
conduct the following test.
1. Turn the ignition key to the ON position. The display should illuminate Voltage Display
and display 000.0V. If not, remove the control panel and check the 12- Adjustment
pin connector on the back of the digital display. The red wire should Fig. 71
have 12VDC battery voltage. If not, then inspect the continuity of the
red wire through to the 6-pin connector at the voltage regulator for
breaks or shorts (see section 4.13, Fig. 27) and repair or replace
accordingly. If the display has 12VDC battery voltage at the red wire,
but fails to illuminate or populate the display when the ignition key is
turned ON, then replace the digital display and reinstall the control
panel.
2. Start the generator. The digital display should illuminate and display
the current voltage. Use a voltmeter to read the voltage between the
hot and neutral contacts of one of the 20A receptacles on the control
panel. The voltmeter and display voltage should agree within a volt or
so (the voltmeter may respond to a voltage change more quickly than
the display). If the voltage displayed does not agree with the voltmeter,
proceed to step 3.
3. Remove the control panel. Locate the trim pot located in the hole on
the top of the backside of the LCD display (Fig. 71). Adjust the trim pot
until the displayed voltage agrees with the volt meter reading at the
20A receptacle. If the displayed voltage cannot be made correct,
63 PH2400PRi/E SM, Rev. 2019-02-13

check the continuity of the yellow and purple wires from the 12-pin display connector
through to the 14-pin connector of the inverter. If there are no wiring issues found or
fixing the wiring issues has not restored proper voltage display, then replace the digital
display and reinstall the control panel.
5.2.2.2 Amperage and Wattage Display Fields
The amperage and wattage displayed by the digital display is taken directly from the
amperage loading signal from the inverter. Since the information for both of these displays
comes from the same signal, a loss of this signal will affect both displayed values
simultaneously. If it is suspected that the amperage and wattage displayed is not correct,
conduct the following test.
1. Turn the ignition key to the ON position. The display should illuminate and display 00.0A.
If not, remove the control panel and check the 12-pin connector on the back of the digital
display. The red wire should have 12VDC battery voltage. If not, then inspect the
continuity of the red wire through to the 6-pin connector at the voltage regulator for
breaks or shorts (see section 4.13, Fig. 27) and repair or replace accordingly. If the
display has 12VDC battery voltage at the red wire, but fails to illuminate or populate the
display when the ignition key is turned ON, then replace the digital display and reinstall
the control panel.
Amperage Display
2. Start the generator. The digital display should illuminate and display Adjustment
0.00A and 0000W. Plug a small load into one of the receptacles and Fig. 72
measure the amperage draw using an amp meter. The amp meter and
display amperage should agree within ±5% (the amp meter may
respond to amperage change more quickly than the display). Multiply
the measured amperage times the displayed voltage (or measure the
voltage at an empty AC receptacle) and compare it to the displayed
wattage. The calculated and displayed wattage values should be
within 5-10% of each other. If the displayed amperage and wattage
are not correct, proceed to step 3.
3. Shutdown generator and remove the control panel. Locate the trim pot
located in the hole on the top of the backside of the LCD display (Fig.
72). Adjust the trim pot until the displayed amperage agrees with the
amp meter reading. If the displayed amperage cannot be made
correct, check the continuity of the yellow and purple wires from the
12-pin display connector through to the 14-pin connector of the
inverter. If there are no wiring issues found or fixing the wiring issues
has not restored proper amperage display, then replace the digital
display and reinstall the control panel.
4. The displayed wattage is a calculated value based on the displayed amperage and
voltage. If proper amperage and voltage are being displayed, the wattage should also be
correct. If this is not the case, then replace the digital display.
5.2.2.3 Hour Meter

The hour meter should read the total generator run time in hours, since its first start. It is an
integral part of the digital display. The hour meter should be running any time there is
120VAC output to the receptacles on the control panel. Complete step 1 of section 5.2.2.1 for
the voltage display field, to make sure the digital display is getting the proper voltage it needs
to operate. If the display passes step 1 but the hour meter fails to begin recording time after
0.1hrs (6 min.) has passed, then replace the digital display.
64 PH2400PRi/E SM, Rev. 2019-02-13

5.2.2.4 Fuel Level Display
The fuel level is displayed in the bottom data field of the digital display. It is represented as a
scale of 0-5 bars (0 bars=empty, 5 bars=full). It gets its signal from an electronic fuel gauge
sending unit that is part of the fuel pump assembly. If it is suspected the fuel level display is
not correct conduct the following test.
▪ It should be noted that when the key is first turned on, the fuel gauge goes
through an initialization process. It will display all five bars for a few seconds, and
then begin to display the actual fuel tank level.
1. Follow steps 2-10 in section 5.3 to remove the outer case, leaving the control panel
connected.
2. Disconnect the 3-pin connector on the top of the fuel pump/gauge assembly.
3. Check the continuity of the red-black wire coming from the digital display through the 16-
pin control panel connector and to the 3-pin connector of the fuel pump/gauge assembly.
It should have no resistance. Repair or replace the wires as necessary.
4. Start the generator and connect the red-black wire of the 3-pin connector to chassis
ground with a jumper wire while watching the fuel level display on the digital display. The
fuel level should drop to zero bars (empty) when the wires are jumped. This indicates a
good display and that the fuel gauge sending unit needs inspected. If the fuel level
display does not change to empty when the wires are jumped, replace the digital display.
5. Follow steps 2-10 in section 5.3 to remove the outer Fig. 73
case and gain access to the fuel pump/gauge
assembly (Fig. 73). Gently pry the sending unit out
with a broad, slotted screwdriver, working your way
around it as required.
6. Put an ohmmeter across the pins of the 3-pin
connector on top of the pump assembly that connect
to the red-black wire and the yellow-green wires.
Hold the body of the sending unit so the float can
hang in the “EMPTY” position. The ohmmeter should
read 10-15Ω. Lift the float slowly to the “FULL”
position (see Fig. 73) while watching the ohmmeter.
It should gradually increase to 150-160Ω. Watch
closely for open spots during the transition. If the fuel
gauge sending unit does not operate in the 10-160Ω
range, or you find open spots during the transition,
replace the fuel pump/gauge assembly. Re-install in
the reverse order of removal.
65 PH2400PRi/E SM, Rev. 2019-02-13

5.2.2.5 Low Oil Indicator Light
The Low Oil Indicator Light will illuminate steadily if the engine is low on oil, and blink on and
off repeatedly to indicate that the ECU has stored EFI fault codes. If both conditions are true,
it will stay on steadily until the low oil condition is remedied, and then blink repeatedly. If it is
suspected that the engine is low on oil, but the light has not illuminated (see section 4.7.1 to
check the oil level sensor), or the ECU has generated fault code 0650, then conduct the
following test to determine if the indicator light is faulty.
1. Remove the control panel to gain access to the back of the digital display.
2. Turn the ignition key to the ON position.
3. Find the pink wire coming out of the back of the digital display and going to the 16-pin
control panel connector. Connect a jumper wire from the negative terminal of the battery
to the pink wire while watching the low oil indicator light. It should illuminate red when the
pink wire is grounded. If it does not, replace the digital display.
5.2.2.6 Fault Code Reset Button
The Fault Code Reset Button is used to read the fault codes stored by the ECU. It is also
used to erase the codes, as necessary, during the diagnostic process and after the repair
process is complete.
To read the fault codes, while the ignition key is on, press the button briefly and the display
will cycle through the fault codes in the Wattage (P) data field of the digital display. Fault
codes are erased by holding the Fault Code Reset Button down for 10 seconds or more
while the key is in the on position. The key must then be turned off to complete the process.
If the indicator light is blinking on and off repeatedly (indicating there are fault codes to read)
but depressing the Fault Code Reset Button does not cause the fault codes to display in the
wattage field of the display, then conduct the following test.
1. Remove the control panel to gain access to the back of the digital display and the 16-pin
control panel connector.
2. Remove the spark plug access cover to gain access to the 18-pin ECU connector (see
Section 5.1.2).
3. Find the green-red wire coming out of the back of the digital display.
4. Check the continuity of the green-red wire from the 12-pin digital display connector,
through the 16-pin connector of the control panel, and all the way to the 18-pin connector
of the ECU (see the wiring diagram in section 1.3). Repair any breaks, shorts, or dirty
connections and verify the resistance is at or close to 0Ω.
5. Once it has been verified that there are no wiring issues, if the Fault Code Reset Button
still fails to work, replace the digital display.
66 PH2400PRi/E SM, Rev. 2019-02-13

5.3 Removing Outer Case
Much of the major work on this generator requires that the outer case be removed for access to the
engine or generator components. Follow the steps below to remove the outer case.
▪ Do not leave the generator on its side for an extended period of time to avoid oil
migrating into the combustion chamber.
2. Lay the generator on its side (maintenance door up) and remove the 4 bolts in the center of
the feet (Fig. 74) and take off the handle/wheel assembly.
3. Remove the 3 outer case screws & nuts that hold the lower portion of the outer case
together (Fig. 74).
Outer Case
Screws
Fig. 74
Handle/Wheel
Assembly Bolts
4. Upright the generator and remove the 4 control panel frame screws (Fig. 75). Leave the
control panel connected and carefully lay it down.
5. Remove the 4 exhaust grille screws and remove the grille (Fig. 76).
Fig. 75 Fig. 76
67 PH2400PRi/E SM, Rev. 2019-02-13

6. Pull out the recoil rope out a few inches and remove the rope guide screw shown in (Fig.
77). Once the screw is removed, both the guide and the recoil handle can be fed through the
hole uncovered by removing the rope guide. This will allow the case to be removed, while
leaving the recoil handle resting against the recoil cage inside.
7. From the right side of the generator, remove the 3 remaining Phillips head side cover
screws (Fig. 77). The nuts for these bolts are captured in the opposite side of the case but
do sometimes come free during disassembly. Place a magnet over the opposite hole as
these screws are removed to catch the nuts if they comes free. If they do not come free,
then they will remain captured during the disassembly/reassembly process. Do not over
tighten these screws during reassembly, as that runs the risk of spinning the captured nuts
in their cavities. This makes future disassembly much more difficult.
8. Pull the right-side case away from the generator, leaving the fuel tank behind.
9. Remove the left-side case and leave the fuel tank resting on top of the inverter mount. It
may be left there until reassembly.
10. Reassemble the outer case by using these steps in reverse order. Take care to insert the
ends of the fuel door pivot rod in the case halves (Fig 78), and put the recoil rope and guide
through the its hole, before screwing the halves of the case together.
Fig. 77
Outer Case
Screws
Rope Guide
Screw
Fig. 78
68 PH2400PRi/E SM, Rev. 2019-02-13

5.4 Outer Generator Housing
5.4.1 Outer Housing Exploded View
Fig. 79 Fuel Door Spark Plug
Access Door
Fuel Door
Pivot Rod
Exhaust Grille
Air Cleaner
Fuel Tank
Carbon Canister Right Case
Maintenance Panel Frame

Door
Control Panel
Battery
Left Case Handle & Wheel Kit

Battery Access
Door
69 PH2400PRi/E SM, Rev. 2019-02-13

5.5 Recoil Starter
5.5.1 Recoil Starter / Removal / Replacement
3. Disconnect the fuel line, tank vent hose, and fuel pump connector, then remove the fuel tank.
4. Remove the battery box, disconnect remote receiver if necessary (Fig. 80).
5. Remove the inverter (Fig. 80).
6. Remove the 3 M6 flange bolts and remove the recoil assembly (Fig. 81).
7. Replace the recoil starter using these steps in reverse order.
Fig. 80 Fuel Tank Fig. 81
Battery Box Inverter
70 PH2400PRi/E SM, Rev. 2019-02-13

5.6 Starter Motor
5.6.1 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).

2. Disconnect the cable from the starter relay (Fig. 82).
3. Attach a 10-12 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 5.6.2).
4. 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, and test the
starter relay (section 5.7).
Cable from the Starter Relay

Fig. 82
Starter
Motor
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5.6.2 Starter Removal/Replacement
2. Follow steps 2-10 in section 5.3 for removing the outer case.
3. Remove the two starter mounting bolts and remove the starter (Fig. 83).
4. Remove the cable from the starter.
5. Replace the starter by using these steps in reverse order.
Fig. 83
Starter Cable
Starter Relay
Starter
Mounting
Bolts
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5.7 Starter Relay
The starter relay is bolted to the chassis below Fig. 84 Starter
the starter, next to the voltage regulator (Fig. 84). Relay
Before beginning to test the starter relay, make
sure the battery is fully charged and the terminal
connections are clean and tight (section 3.2).
Follow the steps below to gain access to the
starter relay. The starter relay can be tested on
(5.7.1) or off (5.7.2) the generator.
1. Follow steps 2-10 in section 5.3 to
remove the outer case.
2. After conducting the starter relay tests, re-
assemble using the steps in the reverse
order.
5.7.1 Testing the Starter Relay on the 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.
2. Verify that there is 12V positive battery voltage at the battery terminal of the starter relay
(Fig. 61). 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. 85). 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, or turns more slowly
than when jumped directly to the battery, check the wire between the relay and the starter
(Fig. 86) for breaks, shorts, high resistance, or dirty/loose connections. Repair as necessary.
6. If the starter cable is in good repair, but the starter still turned slowly in step 5, conduct a
bench test of the starter relay (section 5.7.2). Replace the starter relay if necessary. If proper
power is being supplied by the relay to the starter but the starter fails to operate properly see
section 5.6 for starter service.
Cable from
Fig. 85 Battery Starter Relay
Terminal Starter
motor Fig. 86
Terminal
Start Wire
from Starter
Ignition Motor
Switch
Chassis
Ground
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5.7.2 Bench Testing the Starter Relay
1. Follow steps 1-10 in section 5.3 to remove the outer case. Remove the starter relay from the
chassis (Fig. 84).
2. 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. 87).
Resistance 2.5 – 6.0 Ω
3. Check the function of the starter 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. 88). The resistance
should be at, or near 0Ω. If there is no continuity, or a resistance of ≥0.1Ω the relay is
defective.
▪ There must only be continuity between the battery and starter terminals when
the relay is activated.
Checking Coil Resistance

Fig. 87
Checking Continuity
Fig. 88
Connect to 12V
Connect to positive battery
negative battery terminal
terminal
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5.8 Intake Fan Cover Removal/Replacement
3. Follow steps 3-5 in section 5.5.1 to remove the recoil starter.
4. Disconnect the wiring harness from its hold downs on the intake fan cover (Fig. 89).
5. Remove the ignition coil spark plug cap (Fig. 89).
6. Remove the 3 intake fan cover bolts (Fig. 89) and remove the intake fan cover.
7. Replace the intake fan cover using these steps in reverse order.
Fig. 89 Wiring
Harness
Ignition
Coil
Intake Fan
Cover Bolts
Locations
75 PH2400PRi/E SM, Rev. 2019-02-13

5.9 Stator and Rotor
5.9.1 Stator Inspection
1. Follow steps 1-10 in (section 5.3) for removing the outer case to gain access to the stator
connections.
2. Locate the voltage regulator mounted on the chassis next to the starter relay and remove the
mounting bolt (Fig. 92).
3. Pull out the voltage regulator and locate and unplug the 2-pin connector to the DC windings
(Fig. 91).
4. Check the resistance of the stator DC windings as described below. Replace the stator if it is
out of range.
5. Locate the 6-pin harness near the inverter and unplug it (Fig. 90).
6. Check the main and sub windings resistances as described below. Replace the stator if they
are out of range.
DC charging windings
Measure the resistance between the two blue terminals at the 2-pin connector.
Blue-Blue
Resistance
0.25-1.00 Ω
Sub windings
Measure the resistance between the two sub winding terminals at the 6-pin connector (Fig.67).
White-White
Resistance
0.10-1.00 Ω
Main windings
Measure the resistance between each of the main winding terminals at the 6-pin connector (Fig. 67).
The resistances should be within the range below, and be within 0.2Ω of each other.
Black-Black-Black
Resistance
0.20-2.00 Ω
2-Pin Connector to
Voltage Regulator DC Windings
Fig. 91
Fig. 90
Fig. 92
6-Pin Connector
from Stator
Voltage Regulator Bolt
76 PH2400PRi/E SM, Rev. 2019-02-13
5.9.2 Stator Removal / Replacement
▪ Drain all gasoline from the fuel tank after removing outer case.
▪ Keep the unit away from all heat, flame and sparks.

2. Follow steps 2-4 in section 5.5 to remove the recoil starter.
3. Follow steps 3-5 in section 5.8 to remove the intake fan cover.
4. Remove the CPS, starter cup, and intake fan (Fig. 93).
5. Disconnect 2-pin and 6-pin stator wires (Fig. 90 and Fig. 91 on preceding page).
6. Remove the stator wire cover screw above oil dipstick and remove the stator wire cover (see
inset in Fig. 93).
7. Remove the M16 flange nut from the crankshaft (Fig. 93).
8. Attach an appropriate puller to the rotor using two M6X1 bolts (grade 8.8 or better) and
remove the rotor (Fig. 94).
9. Remove both stator wire hold-down screws and remove the stator wire hold-down (Fig. 95).
10. Remove the two stator mounting bolts marked with yellow circles in Fig. 95 and remove the
stator.
11. Reverse the procedure to reassemble.
Fig. 93
Stator Wire Cover Screw
Stator Stator
Bolts
Rotor
M16 Flange Nut
Intake Fan
Starter Cup
Crankshaft Position
Sensor
Fig. 94 Fig. 95
M6 X 1 Bolts
Stator Wire
Hold Down
77 PH2400PRi/E SM, Rev. 2019-02-13

5.10 Inverter Inspection / Adjustment / Replacement
The inverter is mounted near the front edge of the base plate (chassis) immediately behind the
battery box. 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 will need adjusting before being put into service due to manufacturing
variances. Steps for the adjustment and replacement of the inverter are detailed below.
Inverter Performance Specifications

Output Voltage (0-400W load) 120.5-122.5VAC, 58-62Hz
Rated Output (continuous) 2300W(19.2A) @120-123VAC, 58-62Hz
Maximum Output 2400W(20.0A) @120-123VAC, 58-62Hz
Minimum Output Before Overload 2750W(23.5A) @115-130VAC, 58-62Hz
5.10.1 Inverter Removal / Preparation for Adjustment

2. Remove the battery box but leave the battery connected to the wire harness.
3. Temporaily secure the fuel tank, either in its position above the inverter, or on the bench
beside the generator.
4. Remove the black silcone sealant on the trim pot adjustment screws. Refer to Fig. 96 for the
general area of the trim pots. Refer to Figures 97-99 on the following page for close-up views
of the trim pots after removal of the black silicone sealant.
5. The inverter can be tested still attached to the chassis (Fig. 96). If the inverter is being
replaced, disconnect the connections from the faulty inverter and connect the new one in its
place. Attach the new inverter securely to its mounts on the base pan before testing or
adjusting.
Fig. 96 Adjustment
Trim Pots in
This Area
78 PH2400PRi/E SM, Rev. 2019-02-13

5.10.2 Inverter Adjustment / Replacement
▪ When setting the overload adjustment pot, the inverter will warm up rapidly due
to the lack of forced airflow over the cooling fins. 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.
1. Follow steps 1-5 in section 5.10.1 prior to starting this procedure.
2. Connect a volt meter to one of the 120V 20A duplex receptacles (5-20R). Connect a load
bank and an ammeter to the 120V receptacle.
3. Start the generator.
4. With no load on the generator, adjust the voltage to 121.5V ± 0.7V by turning the voltage
adjustment pot screw (Fig. 99) clockwise to increase and counter-clockwise to decrease.
5. Using a load bank and an ammeter, set the overload adjustment pot (Fig. 98) to trip at 23.5A
following the steps below.
a. Adjust the load bank until the generator output is 23.5A on the ammeter. It may be
necessary to turn the overload adjustment pot screw 1-2 turns clockwise to allow the
output to reach 23.5A without activating an overload.
b. Slowly turn the overload adjustment pot screw counter-clockwise while watching the
output wattage displayed on the digital display. The word “OVER” will begin to appear
intermittently in the wattage display as the overload setting gets closer to the 23.5A
output. Verify that the load bank is still drawing 23.5A from the generator.
c. Continue turning the adjustment screw counter-clockwise while watching the output
wattage display. Stop turning when the word “OVER” is displayed steadily. The
adjustment is now complete.
6. Shut the generator off.
7. Re-seal the screws on both adjustment pots using a drop of touch up paint or silicone
sealant.
8. During this procedure, if it is noticed that the digital display values for voltage and amperage
are not accurate, refer to sections 5.2.2.1 and 5.2.2.2 for adjustment procedures.
9. Reinstall the battery box and fuel tank. Install the outer case using steps 1-10 in (section 5.3)
in reverse order.
Overload Adjustment Pot
Fig. 97
Fig. 98
Voltage Adjustment Pot
Fig. 99
79 PH2400PRi/E SM, Rev. 2019-02-13

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 (Fig. 100).
▪ Keep the unit away from all heat, flame and sparks.
3. Follow steps 3-10 in section 5.1.11 to remove the intake manifold.
4. Remove the carbon canister bolts and remove the carbon canister. This will give access to one
of the left-side engine cover screws; see the blue dotted circle in (Fig. 100).
5. Remove the starter motor cable and the starter motor bolts (Fig. 101). Remove the starter motor.
This gives access to one of the right-side engine cover screws; see the blue circle in (Fig. 101).
6. Remove the left-side and right-side engine cover screws.
Air Cleaner Starter Bolts Starter Cable

Fig. 100 Fig. 101
Carbon Canister Fuel Drain
80 PH2400PRi/E SM, Rev. 2019-02-13

7. Remove the three engine side cover screws circled in Fig. 102.
8. Remove one of the top engine side cover bolts and leave the other attached (Fig. 103). This
keeps the threaded steel backing strap that connects the top of the covers firmly retained on one
of the covers. If both top screws are removed, the steel strap can fall behind the intake fan cover
and into the intake fan. Remove the left and right engine covers.
9. Remove the two muffler bolts from the exhaust manifold (Fig. 104), and the valve cover bolt that
attaches the upper muffler support (Fig. 105). Remove the muffler.
10. Replace the muffler using the steps in reverse order.
Remove one Leave one of the

Fig. 102 engine side engine side cover top
cover top bolt. bolts attached.
Fig. 103
Fig. 104 Valve Cover/Muffler Bolt

Muffler Fig.
Fig.105
82
Muffler Bolts
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5.12 Exploded Engine View
PH2400PRi/E Engine (152F)
82 PH2400PRi/E SM, Rev. 2019-02-13

152F Engine Parts List: PH2400PRi/E
83 PH2400PRi/E SM, Rev. 2019-02-13

84 PH2400PRi/E SM, Rev. 2019-02-13
5.13 Valve Cover / Rocker Arm
5.13.1 Removal / Disassembly
1. Follow steps 1-6 in (section 5.8) to strip the front of the engine down to the rotor.
2. Follow steps 3-9 in (section 5.11) to strip the engine covers and muffler.
3. Remove the remaining three valve cover bolts and remove the valve cover.
4. Turn the rotor to set the piston at top dead center of the compression stroke.
5. The timing mark of camshaft should be vertical to the cylinder head seal (Fig. 106), verify
that the intake and exhaust valves are closed.
6. Remove 4- rocker arm nuts and washers and carefully remove the rocker arm assembly (Fig.
107).
Fig. 106
Timing
Mark
Fig. 107
Alignment
Sleeves
85 PH2400PRi/E SM, Rev. 2019-02-13

5.13.2 Rocker Arm Inspection
● Rocker arm shaft diameter (intake and exhaust)

Standard Service limit
9.96-9.97mm 9.953mm
(0.392-0.393”) (0.391”)
● Rocker arm diameter (intake and exhaust)

10.000-10.015mm 10.040mm
(0.3937-0.3943”) (0.3953”)
86 PH2400PRi/E SM, Rev. 2019-02-13

5.14 Cam and Cylinder Head
5.14.1 Inspection / Reassembly
1. Follow steps 1-6 in section 5.13.1.
2. Remove the two lower head bolts.
3. Remove the timing chain tensioner (Fig. 107).
4. Secure the timing chain with safety wire to prevent it from falling into the crank case.
5. Lift and remove the cam assembly from the head.
6. Carefully inspect the cam lobes and bearings (Fig. 108).
7. Verify proper decompression operation (Fig. 109-111).
● Cam height
29.026-29.086 mm (1.143-1.145”) 29.15 mm (1.104”)
Fig. 107
Timing Chain
Tensioner
Fig. 108 Fig. 109

ON
Cam Bearings
Decompression
Intake Exhaust OFF Fly Weight
Cam Cam
Decompression Decompression
“ON” “OFF”
Fig. 110 Fig. 111
87 PH2400PRi/E SM, Rev. 2019-02-13

8. While holding the safety wire that is attached to the timing chain, carefully remove the
cylinder head and gasket (Fig. 112).
Fig. 112
Timing
Chain
Head
Gasket
5.14.2 Cylinder Head Reassembly

1. Begin this procedure, having completed steps 1-7 in section 5.14.1.
2. Replace the head gasket.
3. Follow steps 1-7 in section 5.14.1 in reverse order. Reference section 5.14.3 for re-
installation of the timing chain tensioner.
▪ Make sure that the piston is at top dead center which can also be confirmed by
locating the crank shaft keyway in the vertical upright position (Fig 113, lower left).
▪ Install the chain onto the cam gear making sure that the timing mark is straight up
before installing the rocker arm assembly (Fig 113).
Fig. 113
Timing
Mark
Timing Mark Position @ TDC, Assembled
Timing
Mark
Crankshaft
Keyway
88 PH2400PRi/E SM, Rev. 2019-02-13

5.14.3 Reinstalling the Timing Chain Tensioner
1. Remove the adjustment cover screw and O-ring (Fig. 114).
2. Replace the tensioner housing gasket.
3. Using a small flat blade screw driver rotate the spring-loaded adjustment screw clockwise to
retract the plunger (Fig. 115).
4. Constant clockwise tension must be applied to the center screw until the tensioner is flush
with the gasket before it is released (Fig. 116).
Fig. 114 Fig. 115 Rotate Screw
Adjustment Screw
Cover and O-Ring
Fig. 116 Retracted Position

Normal
(ready to install)
Position
89 PH2400PRi/E SM, Rev. 2019-02-13

5.14.4 Valves and Valve Spring Inspection
● Free length of valve spring
Spring Standard Service limit
Small 35.5mm (1.397”) 31.1mm (1.224”)
Large 32.8mm (1.291”) 33.8mm (1.330”)
● Valve seat width

1.0mm (0.039”) 2.0mm (0.079”)
● Valve stem diameter

Intake valve 4.975 - 4.99mm (0.1958-0.1964”) 4.92mm (0.1937”)
Exhaust valve 4.955 - 4.970mm (0.1950-0.1951”) 4.90mm (0.193”)
● Valve guide diameter

Intake/Exhaust valve 5.000-5.030mm (0.197-0.198”) 5.060mm (0.199”)
90 PH2400PRi/E SM, Rev. 2019-02-13

5.15 Piston / Connection Rod / Cylinder
Assembly of piston ring
Caution
● Make sure the rings are installed with the manufacturer’s label up.
● Make sure the 1st ring and 2nd ring are not interchanged.
● Make sure the piston rings are free to move after installation.
● Stagger each piston ring gap 120°from each of the other rings.
Manufacturers
厂家标记
Label
第一道环
1st ring
第二道环
2nd ring
Oil 油环
ring
活塞
Piston
活塞销
Piston pin
活塞销卡环
Piston pin ring clip
组装： Compress the ring clips and
Installation:
将前端置于活塞的槽处，用尖嘴钳夹
seat them in the grooves in the ends of
the住另一端，边转动边安装到槽内。
piston pin hole. Make sure that the
gap of the ring clip is not in line with the
不要使卡环的开口对着活塞销孔的缺
groove
口处。 in the piston pin hole.
连杆
组装：
将大端部较长的一侧朝向活塞的
卡环clip “ ”指向的右侧装入活塞。
Ring
91 PH2400PRi/E SM, Rev. 2019-02-13

● Cylinder Bore
52.4000-52.420mm (2.0630-2.0638”) 52.505mm (2.0671”)
● Piston skirt outer diameter

52.360-52.380mm (2.061-2.062”) 52.25mm (2.057”)
10mm
● Side clearance of piston ring

1st and 2nd Ring 0.02-0.06mm (0.0008-0.0024”) 0.15mm (0.0059”)
Oil Ring 0.03-0.18mm (0.001-0.007”) 0.24mm (0.009”)
92 PH2400PRi/E SM, Rev. 2019-02-13

● Piston ring end clearance
Locate the piston ring into cylinder using the piston top, then measure the piston end clearance.

st
1 and 2 Ring nd 0.15-0.25mm (0.0059-0.0098”) 1.0mm (0.039”)
Oil Rings 0.20-0.50mm (0.0078-0.0196”) 1.0mm (0.039”)
● Piston ring height

1st and 2nd Ring 0.97-0.99mm (0.0381-0.0390”) 0.87mm (0.0343”)
Oil Rings 1.85-1.96mm (0.0728-0.0772”) 1.75mm (0.0689”)
93 PH2400PRi/E SM, Rev. 2019-02-13

● Piston pin outer diameter

14.994-15.000mm (0.5903-0.5905”) 14.950mm (0.5886”)
● Piston pin hole inner diameter

15.002-15.008mm (0.5906-0.5909”) 15.050mm (0.5925”)
● Connecting rod small end inner diameter

15.006-15.017mm (0.5908-0.5912”) 15.080mm (0.5937”)
94 PH2400PRi/E SM, Rev. 2019-02-13

This page intentionally left blank.
POWERHOUSE® Products PH2400PRi/E SM Revision 2019-02-13

LKQ Specialty Products Group © LKQ Specialty Products Group 2019
Elkhart, IN 46516 All Rights Reserved
www.powerhouse-products.com

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POWERHOUSE ®

PH2400PRi/E Digital Inverter Generator

Pay special attention to statements preceded by the following words:

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

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

▪ Gives helpful information.

2 PH2400PRi/E SM, Rev. 2019-02-13

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2.2 Important Safety Precautions

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The BCN is found in two locations:

Fig. 1-A Fig. 1-C

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2.7 Alternator Electrical Specifications (Stator Windings)

2.8 Torque Values

12 PH2400PRi/E SM, Rev. 2019-02-13

3.1 Maintenance Schedule

Regular Service period. Perform at every indicated month or operating hour

Fuel line Check Every 2-years (Replace as necessary) (3)

Valve clearance Check / Adjust O (3)

Charge monthly during long term storage.

Expected battery life is 2 years, but can be affected by operating environment.

13 PH2400PRi/E SM, Rev. 2019-02-13

Follow the steps below for removal of the battery.

5. Slide the battery out of the battery box (Fig. 3).

14 PH2400PRi/E SM, Rev. 2019-02-13

1. Remove the maintenance door.

Fig. 4 Oil Dipstick

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1. Remove the maintenance door.

Engine oil capacity: 15.6 oz. (460 ml)

16 PH2400PRi/E SM, Rev. 2019-02-13

17 PH2400PRi/E SM, Rev. 2019-02-13

Spark Plug Type A7RTC

Spark Plug Resistance 3 - 9 kΩ

Spark Plug Gap 0.6 - 0.7mm (0.024” - 0.028”)

Torque valve is 10-12 Nm (7-9 ft-lbs)

18 PH2400PRi/E SM, Rev. 2019-02-13

19 PH2400PRi/E SM, Rev. 2019-02-13

Intake 0.10±0.02mm (0.004”±0.001”)

8. If adjustment is necessary, proceed as follows.

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1. Verify the ignition is OFF and the battery is disconnected.

22 PH2400PRi/E SM, Rev. 2019-02-13

Fig. 15 Spark Arrestor Muffler Grille

23 PH2400PRi/E SM, Rev. 2019-02-13

Troubleshooting Section Legend

4.1 Battery Charge Requirements

24 PH2400PRi/E SM, Rev. 2019-02-13

Check the 20A in-line fuse located on the Blown

Abnormal Replace ignition switch and/or repair

Repair ground. Clean wire ends and

25 PH2400PRi/E SM, Rev. 2019-02-13

Charge battery using recommended

Check the fuel level. No fuel

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