CUMMINS EGMBH/P1100i Operator's Manual

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Page 1

Operator Manual

50 Hz Portable Inverter Generator Set

EGMBH / P1100i

English 04−2008 914−0117 (Issue 2)

Page 2

For Parts Ordering and Technical Support

Please Contact

Cummins

50 – 52 Diagonal Road

Pooraka

South Australia 5082

Parts phone: 08 8368 4358

Service phone: 08 8368 4308

Cummins Power Generation Australia 50-52 Diagonal Road Pooraka, SA 5095 Tel: (61 8) 8368 4300 Fax: (61 8) 8260 3055 sthpac.enquiries@cummins.com

Page 3

STOP

RUN

CHOKE

OUT PUT

3 4

ON OFF

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STOP

RUN

CHOKE

STOP

RUN

CHOKE

STOP

RUN

CHOKE

1 2

5 mm

1 2

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FOREWORD

Thank you very much for purchasing a CUMMINS GENERATOR. This manual covers operation and maintenance of the CUMMINS GENERATOR. This CUMMINS GENERATOR can be used for general electrical equipments, appliances, lamps, tools as an AC power source. With regards to DC application, the terminals are used only for charging 12 volt battery. Never use this generator for any other purposes.

Please take a moment to familiarize yourself with the proper operation and maintenance procedures in order to maximize the safe and efficient use of this product.

Keep this owner’s manual at hand, so that you can refer to it at any time.

Due to constant efforts to improve our products, certain procedures and specifications are subject to change without notice.

When ordering spare parts, always give us the MODEL, PRODUCTION NUMBER (PROD No.) and SERIAL NUMBER (SER No.) of your Product.

Please fill in the following blanks after checking the production number on your product. (Location of label is different depending on the product model.)

CONTENTS

1. SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2. COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3. CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

4. PRE-OPERATION CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

5. OPERATING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

6. WATTAGE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

7. MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

8. "HOW-TO" MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. PERIODIC OPERATION AND INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. PREPARATION FOR STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

PROD No. SER No. (

Label

)

Please refer to the illustrations on the back page of the front cover or back cover for Fig. 1to6indicated in the sentence.

NOTE

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1. SAFETY PRECAUTIONS

Please make sure you review each precaution carefully.

Pay special attention to statement preceded by the following words.

“WARNING” indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.

“CAUTION” indicates a possibility of personal injury or equipment damage if instructions are not followed.

Do not operate the generator near gasoline or gaseous fuel because of the potential danger of explosion or fire. Do not fill the fuel tank with fuel while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel during refueling. If fuel is spilt, wipe it off and let dry before starting the engine.

WARNING

Operate the generator on a level surface. It is not necessary to prepare a special foundation for the generator. However, the generator will vibrate on an irregular surface, so choose a level place without surface irregularities. If the generator is tilted or moved during operation, fuel may spill and / or the generator may tip over, causing a hazardous situation. Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In such a case, piston seizure may occur even if the oil is above the upper level.

WARNING

Pay attention to the wiring or extension cords from the generator to the connected device. If the wire is under the generator or in contact with a vibrating part, it may break and possibly cause a fire, generator burnout, or electric shock hazard. Replace damaged or worn cords immediately.

WARNING

Do not ope rate the gener ator insi de a room , c ave, tunn el, or other insufficiently ventilated area. Always operate it in a well-ventilated area, otherwise the engine may become overheated, and the poisonous carbon monoxide gas contained in the exhaust gases will endanger human lives. Keep the generator at least 1 meter (3 feet) away from any structure or building during use. If the generator must be used indoors, the area must be well-ventilated and extreme caution must be taken regarding the discharge of exhaust gases.

WARNING

Do not place in flammables near the generator. Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other in flammables near the generator.

WARNING

Do not enclose the generator nor cover it with a box. The generator has a built-in forced air cooling system, and may become overheated if it is enclosed. If generator has been covered to protect it from the weather during non use, be sure to remove it and keep it well away from the area during generator use.

WARNING

CAUTION

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Do not contact the generator to a commercial power line. Connection to a commercial power line may short circuit the generator and ruin it or cause electric shock hazard. Use the transfer switch for connecting to domestic circuit.

WARNING

Engine becomes extremely hot during and for some time after operation. Keep combustible materials well away from generator area. Be very careful not to touch any parts of the hot engine especially the muffler area or serious burns may result.

WARNING

No smoking while handling the battery. The battery emits flammable hydrogen gas, which can explode if exposed to electric arcing or open flame. Keep the area well-ventilated and keep open flames/sparks away when handling the battery.

WARNING

Do not operate in rain, in wet or damp conditions, or with wet hands. The operator may suffer severe electric shock if the generator is wet due to rain or snow.

WARNING

Keep children and all bystanders at a safe distance from work areas.

WARNING

If wet, wipe and dry it well before starting. Do not pour water directly over the generator, nor wash it with water.

WARNING

Be extremely careful that all necessary electrical grounding procedures are followed during each and every use. Failure to do so can be fatal.

WARNING

It is absolutely essential that you know the safe and proper use of the power tool or appliance that you intend to use. All operators must read, understand and follow the tool/appliance owners manual. Tool and appliance applications and limitations must be understood. Follow all directions given on labels and warnings. Keep all instruction manuals and literature in a safe place for future reference.

WARNING

Use only "LISTED" extension cords. When a tool or appliance is used outdoors, use only extension cords marked "For Outdoor Use". Extension cords, when not in use should be stored in a dry and well ventilated area.

WARNING

Always switch off generator's AC circuit breaker and disconnect tools or appliances when not in use, before servicing, adjusting, or installing accessories and attachments.

WARNING

Make sure the engine is stopped before starting any maintenance, servicing or repair. Make sure maintenance and repair of the generator set are performed by properly trained personnel only.

CAUTION

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Symbols and Meanings

In accordance with the European requirements (eec Directives),the specified symbols as shown in the following table are used for the products and this instruction manual.

Read the operator's instruction manual.

Stay clear of the hot surface.

Exhaust gas is poisonous. Do not operate in an unventilated room.

Stop the engine before refueling.

Fire, open light and smoking prohibited.

Caution, risk of electric shock.

HOT, avoid touching the hot area.

Do not connect the generator to the commercial power lines.

Engine oil

ON (power and Engine)

Add oil

Battery charging condition

OFF (power and Engine)

Alternating current

Direct current

Plus ; positive polarity

Minus ; negative polarity

OUT-position of a bistable push control

IN-position of a bistable push control

Protective earth (ground)

Fuse

Choke ; cold starting aid

Engine start (Electric start)

Engine stop

Gasoline

Fast

Slow

Fuel start / Open

Fuel stop / Close

P r

Rated power (kW)

COP

Continuous power

COS

Rated power factor

f r

Rated frequency (Hz)

U r

Rated voltage (V)

I r

Rated current (A)

H max

Maximum site altitude above sea-level (m)

T max

Maximum ambient temperature ( )

m Mass (kg)

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2. COMPONENTS (See Fig. 1)

CONTROLS AND INDICATORS

(See Fig. 2)

ENGINE SWITCH (See Fig. 2-q)

Please refer to the illustrations on the back

page of

the front cover or back cover for

Fig.1to

indicated in the sentence.

NOTE

q RECOIL STARTER (HANDLE) w CONTROL PANEL e SIDE PANEL (L) r AIR CLEANER* t FUEL DRAIN SCREW y CARRING HANDLE u TANK CAP COVER i EXHAUST OUTLET o OIL DRAIN PLUG !0 SIDE PANEL (R) !1 OIL GAUGE (OIL FILLER)** !2 SPARK PLUG CAP**

: Inside the SIDE PANEL (L)

** : Inside the SIDE PANEL (R)

The engine switch is designed for easy operation with the interlocking mechanism between the fuel cock and the choke furnished.

OUTPUT LAMP (See Fig. 2-w)

These lamps are turned on in the following conditions; OUTPUT LAMP (Green)

--- The lamp is turned on while generating properly.

OIL SENSOR LAMP (See Fig. 2-e)

When the level of the engine oil falls below the prescribed value, the alarm lamp lights up and the engine stops automatically. When the engine stops due to oil shortage, it can not be started anymore even by pulling the start knob (just the alarm lamp flickers). In such a case, replenish engine oil up to the mouth of the oil filling port. (Refer to page 6 for details about the oil replenishing procedure).

CHOKE

To start the engine, turn the knob to the position. (Choke valve is closed.)

RUN

Keep the knob in this position after the engi ne starts . (The engine can be started with the knob at this position when the engine is warm.)

STOP

To stop the engine, return the knob to the position. (The fuel cock is closed as well.)

CONTROL PANEL

1 2

q OUTPUT LAMP w OIL SENSOR LAMP e AC RECEPTACLES r AC CIRCUIT BREAKER t DC TERMINALS y DC CIRCUIT BREAKER u GROUND TERMINAL i ENGINE SWITCH

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Ambient temperature

Single grade

Multigrade

10W

20W

#20

#30

#40

10W

q FUEL TANK CAP w FUEL FILTER SCREEN e TANK CAP COVER

SIDE PANEL (L.R.) (See Fig. 2-y)

To access the following items for servicing, take the applicable side panel out by removing the screw with screwdriver or coin.

LH-side panel ---- Air cleaner etc.

RH-side panel ---- Oil level gauge, Ignition coil,

Spark plug etc.

FUEL TANK CAP (See Fig. 2-t)

The fuel tank cap is located behind the cover. To open the cover, lift up with the dent portion depressed backward as shown in the illustration. Remove the fuel tank cap by turning counterclockwise.

AC and DC CIRCUIT BREAKER (See Fig. 2-r)

AC and DC circuit breakers shut off electric current when the current exceeds its limit or a malfunction occurs in the connected appliance. Check for excessive current consumption or defects in the appliance. After making sure everything is in order, push the button to the " ON " position.

q BUTTON e IN (ON) w KNOB r OUT (OFF)

If circuit breaker continues to be activated, discontinue use and check generator and/or appliance for malfunction with their respective service representatives. Never interfere with the operation of the circuit breaker knob or keep pushing it in the "ON" position.

CAUTION

4. PRE-OPERATION CHECKS (See Fig. 3)

1. CHECK ENGINE OIL (See Fig. 3-q,w)

Before checking or refilling oil, be sure generator is located on stable and level surface with engine stopped.

■

Remove oil filler cap and check the engine oil level.

■

If oil level is below the lower level line, refill with suitable oil (see table) to upper level line. Do not screw in the oil filler cap when checking oil level.

■

Change oil if contaminated. (See "How-To" Maintenance.)

Oil capacity . . . . 0.35 liters

2. CHECK ENGINE FUEL (SeeFig.2-t,3-e)

Recommended engine oil:

Use 4-stroke automotive detergent oil of API service class SE or higher grade (SG, SH or SJ is recommended). SAE 10W-30 or 10W-40 is recommended for general, all-temperature use. If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area.

Do not refuel while smoking or near open flame or other such potential fire hazards. Otherwise fire accident may occur.

WARNING

■

If fuel level is low, refill with unleaded automotive gasoline.

■

Fuel level should never over the RED marking at the inlet portion. (SeeFig. 3-e-q)

q RED MARKING

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■

Be sure to use the fuel filter screen on the fuel filter neck. (SeeFig. 2-t)

q FUEL TANK CAP w FUEL FILTER SCREEN e TANK CAP COVER

Fuel tank capacity . . . . . . . . . 3.5 liters

■

When using the generator first time or stopping due the fuel running out, pull the recoil handle several times after filling fuel up to the RED marking at the inlet portion of the fuel tank.

Make sure you review each warning in order to prevent fire hazard.

■

Do not refill tank while engine is running or hot.

■

Before filling fuel, turn the engine switch into " " (STOP) position.

■

Be careful not to admit dust, dirt, water or other foreign objects Into fuel.

■

Wipe off spilt fuel thoroughly before starting engine.

■

Keep open flames away.

WARNING

3. CHECKING COMPONENT PARTS

Check following items before starting engine:

■

Fuel leakage from fuel hose, etc.

■

Bolts and nuts for looseness.

■

Components for damage or breakage.

■

Generator not resting on or against any adjacent wiring.

5. GROUNDING THE GENERATOR (See Fig. 3-r)

■

To ground the generator to the earth, connect the grounding lug of the generator to the grounding spike driven into the earth or to the conductor which has been already grounded to the earth.

■

If such grounding conductor or grounding electrode is unavailable, connect the grounding lug of the generator to the grounding terminal of the using electric tool or appliance.

q GROUND TERMINAL w GROUNDING SPIKE

CHECK GENERATOR SURROUNDINGS

Make sure you review each warning in order to prevent fire hazard.

■

Keep area clear of in flammables or other hazardous materials.

■

Keep generator at least 1 meter

away

from buildings or other structures.

■

Only operate generator in a dry, well ventilated area.

■

Keep exhaust pipe clear of foreign objects.

■

Keep generator away from open flame. No smoking!

■

Keep generator on a stable and level surface.

■

Do not block generator air vents with paper or other material.

WARNING

■

When listening the radio near by the generator, the radio sound may be

disturbed

on account of the radio wave

condition and the

radio performance.

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5. OPERATING PROCEDURES (See Fig. 4)

1. STARTING THE GENERATOR

(a) Make sure the appliance is disconnected.

(b)Turn engine switch to " "(CHOKE) position.

(When engine is warm or temperature is high,

start engine with the switch at " " (RUN)

position.) (See Fig. 4-q)

compression point (resistance will be felt), then

return the handle to its original position and pull

briskly. (See Fig. 4-w)

q RECOIL STARTER HANDLE w PULL BRISKLY

(d)After starting, allow the starter handle to return to

its original position with the handle still in your hand.

Check the oil level before each operations as outlined on page 6.

CAUTION

■

Do not connect defective appliances including lines and plugs.

■

Be sure appliances are not connected to generator when starting up. Starting the generator with an appliance connected could result in damage to the generator and/or appliance and in personal injury.

CAUTION

NOTE

When engine fails to start after several attempts, repeat the starting procedures mentioned above with the engine switch placed at " " (RUN) position.

(e) After 20 to 30 seconds of warm-up is completed,

turn the engine switch to " " (RUN) position. (See Fig. 4-e)

(f) Make sure the output lamp is on. This indicates

that the generator is properly operating.

NOTE

Please consult with the authorized CUMMINS dealer if the output lamp is turned off during the proper operation.

■

Make sure that the appliance is switched OFF before connecting it to the generator.

■

Do not move the generator while it is running.

■

Be sure to ground the generator if the connected appliance is grounded. Failure to ground unit may lead to electrical shock.

WARNING

2. USING ELECTRIC POWER

(1) AC APPLICATION (See Fig. 4-r)

(a) Make sure the output lamp is turned on.

(b) Turn off the switch(es) of the electrical

appliance(s) before connecting to the generator.

into the receptacle.

■

Be sure to ground the generator if the connected electrical device is grounded.

■

Failure to ground the unit could lead to electrical shock.

WARNING

Do not put foreign objects into the plug receptacle.

CAUTION

■

Check the amperage of the receptacles, and be sure not to take a current exceeding the specified amperage.

■

Be sure that the total wattage of all appliances dose not exceed the rated output of the generator.

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(2) DC APPLICATION (See Fig. 4-t)

The DC terminal is used only for charging 12 volt batteries. It provides up to 12V-8.3A (100W) of maximum power.

q Positive terminal (RED) w Negative terminal (BLACK)

CONNECTION OF CABLE :

■

Connect positive terminal (red) on generator to positive (+) terminal on battery.

■

Connect negative terminal (black) on generator to negative (

) terminal on battery.

SAFETY PRECAUTIONS WHILE CHARGING

■

An explosive hydrogen gas is discharged through vent holes in the battery during the charging process. Do not allow spark or open flame around the generator or battery during the charging process.

■

Electrolyte fluid can burn eyes and clothing. Be extremely careful to avoid contact. If injured, wash the affected area immediately with large quantities of water and consult a doctor for treatment.

■

When charging a large capacity battery or totally discharged battery, excessive current may force the DC breaker to turn off. In such cases, use a battery charger to charge a large battery with AC output.

■

Battery defects may cause the DC breaker to turn off. Check the battery before replacing the DC breaker.

3. STOPPING THE GENERATOR

(a) Turn off the power switch of the electric

equipment and unplug the cord from receptacle of the generator.

(b) Allow the engine about 3 minutes to cool down

at no load before stopping.

(STOP). (See Fig. 4-y)

4. OIL SENSOR (See Fig. 4-u)

(a) The oil sensor detects the fall in oil level in the

crankcase and automatically stops the engine when the oil level falls below a predetermined level.

(b) When engine has stopped automatically, switch

off generator's AC circuit breaker, and check the oil level. Refill engine oil to the upper level as instructed on page 6 and restart the engine.

procedures, check the oil level

q OIL SENSOR

Do not remove OIL SENSOR PROBE when refilling with oil. Remove oil filler cap on the opposite side of carburetor.

CAUTION

(d) Turn on the switch of the appliance.

NOTE

When the AC circuit breaker turns off during operation, the generator is over loaded or the appliance is defective.

Stop the generator immediately, check the appliance and / or generator for overloading, and have repaired as necessary by Cummins dealer or service shop.

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■

Electrical loads such as incandescent lamps and hot plates require the same wattage to start as is needed to maintain use.

■

Loads such as fluorescent lamps require 1.2

to 2 times the indicated wattage during start-up.

■

Loads for mercury lamps require 2 to 3 times the indicated wattage during start-up.

■

Electrical motors require a large starting current. Power requirements depend on the type of motor and its use. Once enough "surge" is attained to start the motor, the appliance will require only 50% to 30% of the wattage to continue running.

■

Most electrical tools require 1.2 to 3 times their wattage for running under load during use. For example, a 5000 watt generator can power a 1800 to 4000 watt electrical tool.

■

Loads such as submersible pumps and air compressors require a very large force to start. They need 3 to 5 times the normal running wattage in order to start. For example, a 5000 watt generator would only be able to drive a 1000 to 1700 watt pump.

Some appliances need a "surge" of energy when starting. This means that the amount of electrical power

needed to start the appliance may exceed the amount needed to maintain its use. Electrical appliances and tools normally come with a label indicating voltage, cycles / Hz, amperage (amps) and electrical power needed to run the appliance or tool. Check with your nearest dealer or service center with questions regarding power surge of certain appliances or power tools.

6. WATTAGE INFORMATION

To determine the total wattage required to run a particular electrical appliance or tool, multiply the voltage figure of the appliance/tool by the amperage (amps) figure of same. The voltage and amperage (amps) information can be found on a name plate which is normally attached to electrical appliances and tools.

NOTE

The following wattage chart is general guide only. Refer to your specific appliance for correct wattage.

Applicable Wattage

(approx. W)

50 Hz

700 350 250 150

Applications

Incandescent lamp, Heater Fluorescent lamp, Electric tool Mercury lamp Pump, Compressor

VOLTAGE DROP IN ELECTRIC EXTENSION CORDS

When a long electric extension cord is used to connect an appliance or tool to the generator, a certain amount of voltage drop or loss occurs in the extension cord which reduces the effective voltage available for the appliance or tool. The chart below has been prepared to illustrate the approximate voltage loss when an extension

cord of 300 feet

(approx. 100 meters) is used to connect an appliance or tool to the generator.

Nominal

cross

section

A.W.G.

Allowable

current

No.of strands

/ strands dia.

Resistance

Current Amp.

No./mm

Ω/100m

No. A 1A 3A 5A 8A 10A 12A 15A

0.75 18 7 30/0.18 2.477 2.5V 8V

12.5V

─ ─ ─ ─

Voltage drop

1.27 16 12 50/0.16 1.486 1.5V 5V 7.5V 12V 15V 18V

─

2.0 14 17 37/0.26 0.952 1V 3V 5V 8V 10V 12V 15V

3.5 12 to 10 23 45/0.32 0.517

─

1.5V 2.5V 4V 5V 6.5V 7.5V

5.5 10 to 8 35 70/0.32 0.332

─

1V 2V 2.5V 3.5V 4V 5V

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7. MAINTENANCE SCHEDULE

NOTE : (* )

■

Initial oil change should be performed after first twenty (20) hours of use. Thereafter change oil every 100 hours.

■

Before changing the oil, check for a suitable way to dispose of the old oil. Do not pour it down sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instructions on proper disposal.

DAILY

■

Check oil level.

■

Check all components according to "PRE-OPERATION CHECKS."

EVERY 50 HOURS

■

Wash cleaner element. -more often if used in dirty or dusty environments.

■

Check spark plug, clean if necessary.

EVERY 100 HOURS

■

Change engine oil. *-more often if used in dusty or dirty environments.

EVERY 200 HOURS

■

Adjust spark plug gap.

■

Clean fuel strainer.

EVERY 500 HOURS

■

Replace spark plug and cleaner element.

■

Clean and adjust carburetor,valve clearance, and valve seat along with cylinder head.

EVERY 1,000 HOURS

(24 MONTHS)

■

Inspect control panel parts.

■

Check rotor and starter.

■

Replace engine mount rubber.

■

Overhaul engine.

■

Change fuel lines.

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2. SERVICING THE AIR CLEANER

(See Fig. 5-w)

Maintaining an air cleaner in proper condition is very important. Dirt induced through improperly installed, improperly serviced or inadequate elements damages and wears out engines. Keep the element always clean.

(a)

Unhook the cover and remove the cleaner element.

q ELEMENT w AIR CLEANER COVER

(b) Paper element: Clean by tapping gently to

remove dirt and blow off dust. Never use oil. Clean paper element every 50 hours of operation, and replace element every 200 hours or once a year.

(c)

Urethane form : Wash the element with fresh water. Squeeze out the water then dry the element. (Do not twist.)

3. CLEANING AND ADJUSTING

SPARK PLUG (See Fig. 5-e,r)

q SPARK PLUG w PLUG WRENCH

(a) If the plug is contaminated with carbon, remove

it using a plug cleaner or wire brush.

(b) Adjust the electrode gap to 0.6 to 0.7 mm

8. "HOW-TO" MAINTENANCE (See Fig. 5)

1. ENGINE OIL CHANGE (See Fig. 5-q)

q OIL DRAIN PLUG

■

Change engine oil every 50 hours. (For new engine, change oil after 20 hours.)

(a) Drain oil by removing the drain plug and the oil

filler cap while the engine is warm.

(b)

Reinstall the drain plug and fill the engine with oil until it reaches the upper level on the oil filler cap.

■

Use fresh and high quality lubricating oil to the specified level as directed on page 6. If contaminated or deteriorated oil is used or the quantity of the engine oil is not sufficient, the engine damage will result and its life will be greatly shortened.

4. CHECKING CARBON BRUSH (See Fig. 5-t)

If the brush become excessively worn, its contact pressure with the slip ring changes and causes a roughened surface on the slip ring, resulting in irregular generator performance.

Check the brush every 500 hours or if generator performance is irregular.

If the brush is 5 mm long or less, replace it with a new one.

q BRUSH HOLDER w BRUSH e 5 mm r M5 BOLT : 1 pc.

(a) Disconnect the wire connector and remove the

brush.

(b) Carefully note the brush direction and relative

position with the slip ring when installing new brush.

5. SPARK ARRESTR

The spark arrester must be cleaned regularly to keep it functioning as designed. A clogged spark arrester :

■

Prevents the flow of exhaust gas

■

Reduces engine output

■

Increases fuel consumption

■

Makes starting difficult

If the engine has been running, the muffler and the spark arrester will be very hot. Allow the muffler to cool before cleaning the spark arrester.

How to remove the spark arrester

(a) Remove the flange bolts from the muffler cover

and remove the muffler cover.

(b) Remove the special screw from the spark

arrester and remove the spark arrester from the muffler.

SPARK

ARRESTER

SCREEN

SCREW

MUFFLER

Spark plug : BMR4A (NGK)

Make sure the engine is stopped before starting any maintenance, servicing or repair.

CAUTION

NOTE

It is recommended to use ear protection when performing operation, maintenance and repair of the generator set.

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Page 18

PERIODIC OPERATION AND INSPECTION

When furnishing the generator as emergency electric power source, periodic operation and inspection are needed.

Fuel (gasoline) and engine oil will be deteriorated with time, and this causes that the engine is difficult to start and as the results improper engine operation and fault.

Since the fuel (gasoline) will be deteriorated with time, replace fuel (gasoline) with fresh one periodically; once every three (3) months is recommended.

CAUTION

(a) Check the fuel (gasoline), engine oil and air

cleaner.

(b) Start engine.

run the engine for over ten minutes.

(d) Check for the following items;

■

Proper engine running.

■

Adequate output and the indicator lamp turned on properly.

■

The engine switch normally operated.

■

No leakage of engine oil and fuel (gasoline).

10. TRANSPORTING

When transporting the generator, make sure that

the fuel (gasoline) should be drained from the tank.

(a) Turn the engine switch to the " " (STOP)

position.

(b) Drain the fuel from the tank.

position.

■

To prevent fuel spillage due to the vibration and impact, never transport the generator with the fuel (gasoline) filled in the tank.

■

Secure the tank cap thoroughly.

■

To avoid the risk of the gasoline flammability, never leave the generator in an area exposed to direct sunlight or high temperatures for a long time.

■

Keep the fuel (gasoline) in the exclusive gasoline storage tank made by steel when transporting.

WARNING

STOP

RUN

CHOKE

TANK CAP COVER

FUEL TANK CAP

■

Do not place any heavy objects on the generator.

■

Select and place the generator in the proper position of the transport vehicle so that the generator not be moved or fallen down. Fix the generator with rope as necessary.

CAUTION

Clean the spark arrester screen

Use a brush to remove carbon deposits from the spark arrester screen. Be careful to avoid damaging the screen.

The spark arrester must be free of breaks and holes. Replace the spark arrester if it is damaged.

Install the spark arrester, and muffler protector in the reverse order of disassembly.

SPARK ARESSTER SCREEN

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Page 19

When generator engine fails to start after several attempts, or if no electricity is available at the output socket, check the following chart. If your generator still fails to start or generate electricity, contact your nearest Cummins dealer or service shop for further information or corrective procedures.

12. TROUBLESHOOTING

Check if engine switch is in its proper position.

Check fuel level.

Check to make sure generator is not connected to an appliance.

Check spark plug for contamination.

Check engine oil level.

Check spark plug for loose spark plug cap.

Turn engine switch to " "(CHOKE) position.

If empty, refill fuel tank making sure not to overfill.

If connected, turn off the power switch on the connected appliance and unplug.

Remove spark plug and clean electrode.

If the engine oil level is low, add the oil to the upper level line on the oil gauge.

If loose, push spark plug cap back into place.

When No Electricity Is Generated at Receptacle :

When Engine Fails to Start:

Check if the AC circuit breaker is turned OFF.

Check AC receptacle and DC terminals for loose connection.

Check to see if engine starting was attempted with appliances already connected to generator.

Stop the engine and check the appliances and/or generator for overloading.

Secure connection if necessary.

Turn off switch on the appliance, and disconnect cable from receptacle. Reconnect after generator has been started properly.

Low power.

Carbon brushes are excessively worm.

Check if the DC circuit breaker

is turned OFF.

Depress the circuit breaker into ON position,

after making sure the electric appliances are

in the normal condition.

11. PREPARATION FOR STORAGE (See Fig. 6)

The following procedures should be followed prior to storage of your generator for periods of 6 months or longer.

■

Drain fuel from fuel tank carefully by disconnecting the fuel line. Gasoline left in the fuel tank will eventually deteriorate making engine-starting difficult.

■

When draining fuel from the fuel tank, use the hand pomp and set it into the refilling port.

(See Fig. 6-q)

■

Remove the drain screw of the carburetor. (See Fig. 6-w)

q DRAIN SCREW

■

Change engine oil.

■

Check for loose bolts and screws, tighten them if necessary.

■

Clean generator thoroughly with oiled cloth. Spray with preservative if available. NEVER USE WATER TO CLEAN GENERATOR !

■

Pull starter handle until resistance is felt, leaving handle in that position.

■

Store generator in a well ventilated, low humidity area.

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Page 20

13. SPECIFICATIONS

MODEL

Rated voltage V

P1100

240

Alternator

Type

AVR

DC output V

Frequency Hz 50

8.3

Maximum output kVA 0.85

Rated output kVA 0.7

Rated power factor 1.0

Over current protector

fuse Breaker

Engine

Model

EH09-2

Type Forced air-cooled, 4-cycle, OHV Gasoline Engine

Displacement mL 85.8

Fuel Automotive Unleaded Gasoline

Fuel tank capacity L

3.5

Rated continuous operation

[Approx.] hours

3.7

Starting system Recoil starter

Dimension

Length mm 490

Width mm 295

Height mm 445

Dry weight kg 25

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Page 21

14.WIRING DIAGRAM

Blk : Black

Wiring color cord

Blk/W : Black/White Blu : Blue

LBlu : Light blue Brn : Brown Brn/W : Brown/White

Grn : Green Grn/W : Green/White Org : Orange

Gry : Gray R : Red W : White

Y : Yellow

Grn/Y : Green/Yellow

W/Blk : White/Black

Pur : Purple

GENERATOR CONTROL PANEL

DC coil

NEON LAMP

OIL LED

Grn/Y

Org

Blu

Earth (ground) terminal

Main coil (1) Main coil (2)

ENGINE

AVR

Field Winding

Brush (+)

Brush (

)

Exciter

coil

Ignition coil

Spark plug

Oil sensor control unit

Oil sensor

Grn/Y BlkBrn

Gry

Engine switch

AC receptacle 240V

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Page 22

Cummins Power Generation

1400 73rd Ave. NE Minneapolis, MN 55432 USA

Phone 1 763 574 5000 Toll-free 1 800 888 6626 Fax 1 763 574 5298 Email www.cumminsonan.com/contact www.cumminsonan.com

CumminsR, OnanR, the “C” logo, and “Performance you rely on.” are trademarks of Cummins Inc.