CUMMINS EGMBR, P2200, P2600, EGMBS Operator's Manual

Operator Manual

Portable Generator Set

EGMBR, P2200

EGMBS, P2600

English 8−2009 914−0113 (Issue 4)

Table of Contents

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

1.1 Exhaust Gas Is Deadly ............................................................................................................ 1

1.2 Gasoline is Flammable / Explosive.......................................................................................... 1

1.3 Generator Voltage is Deadly.................................................................................................... 2

1.4 Moving Parts Can Cause Severe Personal Injury or Death .................................................... 2

1.5 Battery Gases Are Explosive ................................................................................................... 2

1.6 General Precautions ................................................................................................................ 2

2. INTRODUCTION............................................................................................................................. 5

2.1 About This Manual................................................................................................................... 5

2.2 Model Identification .................................................................................................................. 5

2.3 Fuel Requirements................................................................................................................... 7

2.4 Generator Set Assembly Instructions ...................................................................................... 7

2.5 Engine Oil Recommendations ................................................................................................. 8

2.6 How to Obtain Service ............................................................................................................. 8

3. STARTING AND RUNNING THE GENERATOR SET.................................................................... 9

3.1 Control Panel ........................................................................................................................... 9

3.2 Pre-Start Checks...................................................................................................................... 9

3.3 Starting the Generator Set..................................................................................................... 11

3.4 Stopping the Generator Set ................................................................................................... 13

3.5 Powering Tools and Appliances ............................................................................................ 13

3.6 Charging Batteries ................................................................................................................. 15

3.7 Circuit Breakers ..................................................................................................................... 15

3.8 Grounding .............................................................................................................................. 16

3.9 Low Oil Shutdown.................................................................................................................. 16

3.10 Electrical Interference with Communications or Appliances ................................................ 16

3.11 Exercising the Generator Set............................................................................................... 16

3.12 Engine Break-In ................................................................................................................... 16

3.13 Out-of-Service Protection..................................................................................................... 17

4. MAINTENANCE ............................................................................................................................ 19

4.1 Maintenance Schedule .......................................................................................................... 19

4.2 General Inspections ............................................................................................................... 20

4.3 Changing Engine Oil.............................................................................................................. 20

914-0113 (Issue 3) i

Table of Contents 8-2009

4.4 Air Filter Maintenance............................................................................................................ 21

4.5 Fuel Sediment Cup Cleaning................................................................................................. 22

4.6 Spark Plug Maintenance........................................................................................................ 22

4.7 Cleaning the Generator Set ................................................................................................... 24

4.8 Cleaning the Spark Arrester .................................................................................................. 24

5. TROUBLESHOOTING .................................................................................................................. 27

6. SPECIFICATIONS ........................................................................................................................ 31

7. MAINTENANCE RECORD............................................................................................................ 33

8. GLOBAL ADDRESSES................................................................................................................. 35

ii 914-0113 (Issue 3)

1 Safety Precautions

Thoroughly read the Operator Manual before operating the generator set. Safe operation
and top performance can only be obtained when equipment is operated and maintained
properly.

The following symbols, found throughout this manual, alert you to potentially dangerous
conditions to operators, service personnel, and the equipment.

DANGER: This symbol alerts you to an immediate hazard that will result in

severe personal injury or death.

WARNING: This symbol alerts you to a hazard or unsafe practice that can result in

severe personal injury or death.

CAUTION: This symbol alerts you to a hazard or unsafe practice that can result in personal

injury or damage to equipment or property.

1.1 Exhaust Gas Is Deadly

· Operate the generator set outdoors only. Stay away from the exhaust outlet.

· Make sure generator set exhaust will not enter windows, doors, vents, or air intakes of

adjacent buildings, vehicles, or boats.

· NEVER USE THE GENERATOR SET INSIDE a home, garage, crawl space, barn, shed,
cabin, boat, boat house, RV, or tent; or in a confined outdoor space such as an alley, ditch,
parking garage, or courtyard; or in any other space where exhaust can accumulate. Note
that HAZARDOUS CARBON MONOXIDE LEVELS FROM ENGINE EXHAUST CAN
ACCUMULATE INDOORS, EVEN WHEN ALL WINDOWS AND DOORS ARE OPEN AND
FANS ARE RUNNING.

· Even when you use a generator set correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.

· If you feel sick, dizzy, or weak after the generator set has been running, move to fresh air
RIGHT AWAY. See a doctor. You could have carbon monoxide poisoning.

1.2 Gasoline is Flammable / Explosive

· Refuel the generator set outdoors only.

914-0113 (Issue 3) 1

1. Safety Precautions 8-2009

· Static electric sparks caused by fuel flowing through a service station pump nozzle can
ignite gasoline. Never fill the generator set with a service station pump nozzle. Instead, fill
a safety tank sitting on the ground and then slowly transfer fuel to the generator set from
the safety tank.

· DO NOT fill fuel tanks while the engine is running. A hot engine can ignite the fuel.

· To prevent fire due to fuel leakage, always close the fuel valve and let the generator set

cool before transporting it or storing it in a confined space.

· DO NOT SMOKE OR ALLOW AN OPEN FLAME near the generator set. Keep flames,
sparks, electrical switches, pilot lights, electrical arcs, arc-producing equipment, and all
other sources of ignition well away.

1.3 Generator Voltage is Deadly

· DO NOT CONNECT THE GENERATOR SET DIRECTLY TO ANY BUILDING
ELECTRICAL SYSTEM. Back-feed could cause electrocution of utility line workers and
could damage equipment. An approved switching device must be used to prevent
interconnections. A trained and experienced electrician must make electrical connections
when the generator set is used for emergency power.

· Make sure clothing, shoes, and skin are dry when handling electrical equipment.

· Never operate the generator set in rain or snow or when it is sitting on wet ground.

1.4 Moving Parts Can Cause Severe Personal Injury or Death

· Before performing any maintenance on the generator set, disconnect the spark plug wire.

· Always keep hands away from moving parts.

· Do not wear loose clothing or jewelry while servicing the generator set. Loose clothing and

jewelry can become caught in moving parts. Jewelry can short out electrical contacts
causing sparks, flame, and electrical shock.

· Make sure that fasteners and clamps on the generator set are tight. Keep guards in
position over fans, rotors, etc.

1.5 Battery Gases Are Explosive

· Wear safety glasses when servicing batteries.

· Do not smoke.

· To reduce arcing when disconnecting or reconnecting battery cables, always disconnect

the negative (–) cable of the battery first and reconnect it last.

1.6 General Precautions

· Keep children away from the generator set.

· Wear hearing protection when near an operating generator set.

2 914-0113 (Issue 3)

8-2009 1. Safety Precautions

· Keep a multi-class ABC fire extinguisher readily at hand. Class A fires involve ordinary
combustible materials, such as wood and cloth. Class B fires involve combustible and
flammable liquids and gaseous fuels. Class C fires involve live electrical equipment. (ref.
NFPA No. 10).

· Benzene and lead may be found in gasoline and have been identified by some state and
federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or
contact gasoline.

· Used engine oils have been identified by some state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest, inhale, or contact used engine oil or its
vapors.

· Keep the generator set clean and dry at all times. Excess grease and oil can catch fire
and/or accumulate dirt, which can cause overheating.

· Do not store anything on the generator set, such as oil cans, oily rags, chains or wooden
blocks. A fire could result or operation could be adversely affected.

· Do not work on the generator set when you are mentally or physically fatigued or have
consumed alcohol or drugs.

914-0113 (Issue 3) 3

1. Safety Precautions 8-2009

This page is intentionally blank.

4 914-0113 (Issue 3)

2 Introduction

2.1 About This Manual

This manual covers the generator sets listed on the front cover. Study this manual and observe
all of its warnings and precautions. Using and maintaining the generator set properly will result
in longer generator set life, better performance, and safer operation.

2.2 Model Identification

Be ready to provide the generator set model and serial numbers on the generator set nameplate
when contacting Cummins Onan for parts, service, or product information. A typical nameplate
and its location on the generator set is illustrated in the Figures below.

WARNING: Many troubleshooting procedures or replacement of parts present hazards

that can result in equipment damage and severe personal injury or death.
Only trained and experienced service personnnel with knowledge of fuels,
electricity, and machinery hazards should perform service procedures.
Review the Safety Precautions section of this manual.

FIGURE 1. NAMEPLATE LOCATION FOR EGMBR/P2200 AND EGMBS/P2600 GENERATOR

SETS

914-0113 (Issue 3) 5

2. Introduction 8-2009

No. Description No. Description

6 914-0113 (Issue 3)

8-2009 2. Introduction

1 Fuel Tank Cap 6 Recoil Starter Grip

2 Fuel Gauge 7 Battery

3 Choke Lever 8 Control Panel

4 Fuel Valve 9 Muffler

5 Air Cleaner 10 Spark Plug Boot

FIGURE 2. COMPONENT LOCATIONS

2.3 Fuel Requirements

Use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher.

During part of the year, only mandated "oxygenated" gasoline may be available. While
"oxygenated" gasoline is acceptable for use, it is not preferable. Using leaded gasoline will
result in extra maintenance to remove combustion chamber and spark plug deposits. Do not use
starting fluids and do not use gasoline or gasoline additives (de-icers) containing methanol.
Methanol is corrosive to fuel system components.

WARNING: Evaporative starting fluids, such as ether, are highly explosive which can

result in severe personal injury or death. Do not use starting fluids.

CAUTION: Methanol is corrosive to fuel system components. Do not use gasoline or gasoline

additives containing methanol.

CAUTION: Avoid using leaded gasoline because of the extra engine maintenance that will be

required.

WARNING: Gasoline is highly flammable and explosive which can result in severe

personal injury or death. Do not smoke if you smell gasoline or are near fuel
tanks or gasoline-burning equipment, or are in the area sharing ventilations
with such equipment. Keep flames, sparks, electrical switches, pilot lights,
arc-producing equipment, and all other sources of ignition well away from
the area.

2.4 Generator Set Assembly Instructions

1. Remove the generator set from the box.

WARNING: The generator set is heavy. Dropping the generator set can cause severe

personal injury or death. Keep feet and hands clear when lifting the generator
set.

2. Add oil to the generator set (see Engine Oil Recommendations on the following page).

CAUTION: Too little oil can cause severe engine damage. Make sure that the oil level is above

the Add mark on the dipstick.

3. Add gasoline to the fuel tank (see Fuel Requirements on the previous page).

CAUTION: Methanol is corrosive to fuel system components. Do not use gasoline or gasoline

additives containing methanol.

CAUTION: The use of leaded gasoline will require extra maintenance. Avoid using leaded

gasoline.

914-0113 (Issue 3) 7

2. Introduction 8-2009

2.5 Engine Oil Recommendations

Use American Petroleum Institute (API) performance class SL or SJ engine oil or better. Also
look for Society of Automotive Engineers (SAE) viscosity grade oil (see the table below).
Choose the viscosity grade appropriate for the ambient temperature expected until the next
scheduled oil change. Refer to the Specifications section for engine oil capacity.

Single-grade SAE 30 oil is best when temperatures are consistently above freezing. Multi-grade
oils are better when wide temperature variations are expected.

TABLE 1. OIL VISCOSITY VS. TEMPERATURE

Expected Ambient Temperatures SAE Viscosity Grade

30oF (0 C) and higher 30

10oF to 100oF (-12oC to 38oC) 15W-40

0oF to 80oF (-18oC to 27oC)

-20oF to 50oF (-28oto 10oC) 5W-30

10W-30
10W-40

2.6 How to Obtain Service

When calling for service, parts, or product literature (such as the Service Manual or Parts
Catalog) for your generator set, contact the nearest authorized Cummins Onan distributor.
Cummins Onan has factory-trained representatives to handle your requests for generator set
parts and service. For information on contacting Cummins Onan distributors worldwide, go to
the internet site www.cumminsonan.com.

2.6.1 Outside North America

If you are outside North America, call Cummins Onan at 1-763-574-5000 from 7:30 AM to 4:00
PM, Central Standard Time, Monday through Friday, or fax [phone].

2.6.2 Information to Have Ready

Before calling for service, have the following information available:

1. The complete generator set model number and series number. Refer to the Model

Identifcation section of this manual.

2. The date of purchase.

3. The nature of the problem. Refer to the Troubleshooting section of this manual.

8 914-0113 (Issue 3)

3 Starting and Running the Generator

Set

3.1 Control Panel

The control panels for the models covered in this manual are illustrated below. The control
switches, meters, output receptacles, and circuit breaker reset buttons are grouped for
convenient operation.

No. Description No. Description

1 Start/On/Off Switch 4 Earth Ground Lug

2 DC Circuit Breaker Reset 5 Three Schuko Outlets (230V, 16A)

3 AC Circuit Breaker Reset 6 Voltmeter

7 DC Breaker

FIGURE 3. CONTROL PANEL

3.2 Pre-Start Checks

DANGER: EXHAUST GAS IS DEADLY! THE INDOOR USE OF A GENERATOR SET

CAN KILL QUICKLY.

914-0113 (Issue 3) 9

3. Starting and Running the Generator Set 8-2009

Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon
monoxide is poisonous and can cause unconsciousness, severe personal injury, and
death. Symptoms of carbon monoxide poisoning include:

· Dizziness

· Nausea

· Headache

· Weakness and sleepiness

· Throbbing in temples

· Muscular twitching

· Vomiting

· Inability to think coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET INTO FRESH
AIR IMMEDIATELY. Then:

· Seek immediate advice from poison control, medical center, or 911. Be aware that:

· CO symptoms can be mistaken for flu, dehydration, food poisoning, or other illness.

· Injury or death can occur later when in fresh air and apparently recovering.

· Call the fire department to determine when it is safe to re-enter the area.

Operate the generator set OUTDOORS only. Stay away from and upwind of the exhaust
outlet.

Make sure the exhaust will not enter windows, doors, vents, or air intakes of adjacent
buildings, vehicles, or boats.

Never use the generator set inside a home, garage, crawl space, barn, shed, cabin, boat,
boat house, RV, or tent; or in a confined outdoor space such as an alley, ditch, parking
garage, or courtyard; or in any other space where exhaust can accumulate. Hazardous
carbon monoxide levels from generator set exhaust can accumulate indoors even when
windows and doors are open and fans are running.

Even when you use a generator set correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.

If you feel sick, dizzy, or weak after the generator set has been running, move to fresh air
RIGHT AWAY. See a doctor. You could have carbon monoxide poisoning.

10 914-0113 (Issue 3)

8-2009 3. Starting and Running the Generator Set

Before the first start of the day and after every eight hours of operation, perform GENERAL
INSPECTIONS and any scheduled maintenance due, as indicated in the Maintenance

Schedule. If the generator set has been in storage, return it to service as instructed in the
Out-of-Service Protection section.

WARNING: Moving parts can cause severe personal injury or death. Hot exhaust parts

can cause severe burns. Make sure all protective guards are properly in
place before starting the generator set.

WARNING: Gasoline is highly flammable and explosive and can be ignited by static

electric sparks caused by fuel flowing through a service station pump nozzle
which can result in severe personal injury or death. Never fill the generator
set with a service station pump nozzle. Instead, fill a safety tank sitting on
the ground and then slowly transfer fuel to the generator set from the safety
tank.

1. Locate the generator set outdoors in a dry, level place and chock the wheels, if so
equipped.

2. Check fuel and oil levels, and fill as necessary.

WARNING: If the generator neutral supply is not grounded to earth, the user may be left

without ground fault protection, which could result in serious personal injury
or death. Always make sure the generator neutral supply is grounded to
earth before operating the generator set.

3. Connect the grounding lug to earth ground in accordance with the local electrical code.

4. Make sure that all extension cords are in good condition, are rated for outdoor use and
have the proper amp and voltage ratings, and that they are equipped with proper plugs
having grounding blades.

5. Make sure all tools and appliances have been turned off or are disconnected.

3.3 Starting the Generator Set

WARNING: Operating a generator set in an inappropriate environment can result in a fire

which can result in severe personal injury or death. Do not operate the
generator set in hazardous environments where it could ignite flammable
gasses or combustible materials. To avoid the risk of electrocution, never
operate the generator set in rain or snow or when it is sitting on wet ground.
Be careful not to touch or allow any combustible materials to touch the
muffler which can get very hot.

CAUTION: The voltage surge at startup can damage appliances such as TVs, microwave

ovens, computers, etc. Be sure to disconnect all appliances before starting the
generator set.

1. Open the fuel valve (see Figure 4).

2. Pull the choke rod out to close the choke if the engine is cold (see Figure 5).

3. Verify that the On/Off switch is in the ON position.

4. With one hand on the generator, grip the recoil handle with the other hand and pull it out
quickly and smoothly. Repeat as necessary until the engine starts (see Figure 6).

5. As the engine warms up, gradually push the choke rod in.

6. Let the engine warm up for a few minutes before connecting tools or appliances. See

Powering Tools and Appliances.

914-0113 (Issue 3) 11

3. Starting and Running the Generator Set 8-2009

FIGURE 4. FUEL VALVE

No. Description No. Description

1 Choke Lever 3 Closed

2 Open

FIGURE 5. CHOKE ROD

12 914-0113 (Issue 3)

8-2009 3. Starting and Running the Generator Set

FIGURE 6. RECOIL START HANDLE

3.4 Stopping the Generator Set

1. Turn off or disconnect all tools and appliances.

2. Let the generator set run for a few minutes to cool down.

3. Stop the generator set by pressing and holding the On/Off switch in the Off position until
the generator set stops.

4. Close the fuel valve.

WARNING: Gasoline is highly flammable and explosive which can result in severe

personal injury or death. Always close the fuel valve when the engine is not
in use to reduce the risk of fuel spillage.

3.5 Powering Tools and Appliances

CAUTION: Continuous overloading can damage the generator set due to overheating. Make

sure loading is within the generator set nameplate rating.

3.5.1 Connecting Tools and Appliances

TABLE 2. TYPICAL POWER DRAW RATINGS OF COMMON TOOLS AND APPLIANCES

Appliance or Tool Running Watts (Rated)

Ceiling Fan 800 1200

Central Air Conditioner - 10,000 BTU

Central Air Conditioner - 24,000 BTU

Circular Saw - 7¼" 1400 2300

Clock Radio 100 -

Clothes Dryer - Gas 700 1200

Coffee Maker 1500 -

2

2

1500 3000

3800 4950

1

Starting Watts (Peak)

1

914-0113 (Issue 3) 13

3. Starting and Running the Generator Set 8-2009

Computer - 17" Monitor 800 -

Deep Freezer 700 1000

Dishwasher 1500 1500

Electric Water Heater - 40 Gallon

2

4000 -

Furnace Fan 800 1300

Garage Door Opener 750 1200

Hair Dryer 1250 -

Hot Plate 2100 -

Iron 1200 -

Laser Printer 950 -

Lighting 75 -

Microwave Oven 1000 -

Miter Saw - 10" 1650 2400

Oscillating Fan 200 400

Quartz Halogen Work Light 1000 -

Reciprocating Saw 1200 2000

Refrigerator/Freezer 700 1500

Security System

2

500 -

Space Heater 1800 -

Stereo Receiver 450 -

Sump Pump 800 1200

Table Fan - 14" 200 400

Television - 27" 500 -

VCR/DVD Player 100 -

Water Well Pump - 1/3 HP (220V)

2

1000 2000

Window Air Conditioner - 10,000 BTU 1200 2200

1

The wattage values listed in this table are based on estimated wattage requirements. For exact wattage, check the

data plate or the operator's manual for the item you wish to power.

2

These units are usually hard-wired and require a professionally-installed transfer switch.

NOTE: Ratings apply to altitudes up to 1000 feet (304.8 m), 85oF (30oC). Total power available will decrease 3.5% for
each 1000 feet (304.8 m) above 1000 feet and 2.0% for each 10oF (5.5oC) increase in ambient temperature above
85oF (30oC).

1. Make sure the tools and appliances to be connected are rated for the voltages at the
generator set power output receptacles.

2. Note the kW rating on the generator set nameplate.

3. Check the power draw (watts) of each tool or appliance to be connected. The table above
lists typical tool and appliance ratings in watts.

4. Add the watt ratings of all the loads that the generator set will be powering at the same
time. Make sure that total wattage will not exceed the generator kW rating.

14 914-0113 (Issue 3)

8-2009 3. Starting and Running the Generator Set

Example: A generator set rated 2.5 kW (2500 watts) can power one 1500 watt heater, a
500 watt drill and a 100 watt light at the same time (2100 watts altogether). One of these
loads probably will have to be disconnected if some other tool or appliance is to be
powered.

NOTE: A motor draws much more power when starting up than when running. It may

be necessary to power fewer tools or appliances when motors and air
conditioners are cycling on and off.

CAUTION: Excessive power draw can overload the generator set. A motor draws much more

power when starting up than when running. It may be necessary to power fewer
tools or appliances when motors and air conditioners are cycling on and off.

5. Connect the AC power cords to the appropriate receptacles on the control panel. See

Grounding.

3.5.2 High Altitude

Maximum power decreases roughly four percent every 1000 feet (310 meters) of increase in
elevation above sea level. When operating the generator set at altitudes above 1000 feet, it may
be necessary to power fewer loads at the same time.

3.6 Charging Batteries

To reduce arcing, always stop the generator set before connecting or disconnecting the battery
to be charged. Connect the battery to be charged to the DC terminals on the control panel.
Make sure polarity is correct: positive (+) to positive (+); negative (–) to negative (–).

WARNING: Ignition of explosive battery gases can cause severe personal injury or

death. Arcing at battery terminals can ignite battery gases. Ventilate the area
before working on batteries. Wear safety glasses and do not smoke. Always
stop the generator set before disconnecting the battery. Always disconnect
the negative (–) cable first and reconnect it last.

NOTE: The battery on electric-start models has its own charging circuit and

therefore must not be connected to the DC charging terminals.

3.7 Circuit Breakers

If too many tools or appliances are connected, or a tool or appliance fails due to a short circuit,
one or more of the AC or DC circuit breakers on the control panel will trip. Disconnect or turn off
as many tools and appliances as possible and reset the circuit breaker by pushing the reset
button back in. (It takes at least 10 seconds after tripping to reset.) Turn on or reconnect only as
many tools and appliances as the generator set can power.

A tool or appliance probably has a short if it causes a circuit breaker to immediately trip when
connected.

WARNING: Short circuits in faulty electrical tools and appliances can cause

electrocution or fire. Read and follow the tool and appliance manufacturer's
instructions and warnings regarding use, maintenance, and proper
grounding.

914-0113 (Issue 3) 15

3. Starting and Running the Generator Set 8-2009

3.8 Grounding

Ground the generator set to earth ground by connecting a suitable ground wire to the ground
lug terminal on the generator set control panel. The other end of the wire must be connected to
a suitable earth ground according to local electrical codes.

Do not connect grounds from tools or appliances to the Ground Lug terminal. Extension cords
for tools or appliances with grounding blades must have grounding blades.

WARNING: If the generator neutral supply is not grounded to earth, the user may be left

without ground fault protection, which could result in serious personal injury
or death. Always make sure the generator neutral supply is grounded to
earth before operating the generator set.

3.9 Low Oil Shutdown

The generator set automatically stops if it senses low oil level. If the engine stops while running,
or starts but then stops, check the oil level and add oil as necessary. See the Maintenance
section of this manual.

3.10 Electrical Interference with Communications or Appliances

If the generator set causes electrical interference with communications devices, move the
generator set and device farther apart or shut down the generator set while the device is
operating.

3.11 Exercising the Generator Set

Exercise the generator set at least two hours every month if use is infrequent. Run it at
approximately 50 percent capacity. A single two-hour exercise period is better than several
shorter periods. Exercising a generator set drives off moisture, re-lubricates the engine,
replaces stale fuel, and removes oxides from electrical contacts. The result is better starting,
more reliable operation, and longer engine life.

3.12 Engine Break-In

Proper engine break-in is necessary for top performance.

1. Operate the generator set as it is intended to be operated. However, for the first 1-1/2
hours, if possible, run the generator set at 50 percent capacity, occasionally operating at
full power for brief periods. Avoid prolonged low-power operation during break-in.

2. Make sure the engine has oil of the proper viscosity for the ambient temperature. See

Engine Oil Recommendations.

3. Check the oil level twice a day or after every 4 hours of operation during the first 20 hours
of operation. Change the engine oil after the first 20 hours of operation.

16 914-0113 (Issue 3)

8-2009 3. Starting and Running the Generator Set

3.13 Out-of-Service Protection

If you are unable to exercise the generator set regularly, and it will not be in use for more than
120 days, the following storage procedure is recommended. Failure to provide out-of-service
protection can result in difficult starting, rough engine operation, and reduced engine life.

3.13.1 Storing the Generator Set

WARNING: Fuel additives can cause a risk of personal injury. Read and follow the

manufacturer's instructions.

1. Add a fuel preservative and stabilizer to the fuel tank, or let the generator set run out of
fuel. Follow the manufacturer’s instructions for using the fuel additive.

2. Shut the fuel valve and drain the carburetor bowl (see Figure 7).

3. Remove the spark plug. Squirt one tablespoon (about 30 cm3) of clean engine oil into the
spark plug hole. Turn the engine over several revolutions. Replace the spark plug. Pull the
recoil starter handle out slowly until compression is felt.

4. Change engine oil and attach a tag indicating the viscosity of oil used.

5. Store the generator set in a dry, protected area.

No. Description

1 Fuel Drain Bolt

FIGURE 7. CARBURETOR DRAIN

3.13.2 Returning the Generator Set to Service

1. Check the tag on generator set to verify that oil viscosity is correct for the current ambient
temperature. Add or change oil as necessary.

2. Clean the air cleaner if dirty.

3. Open the fuel valve.

914-0113 (Issue 3) 17

3. Starting and Running the Generator Set 8-2009

4. Start the generator set. Initial start-up may be rough and smoky due to the extra oil in the
cylinder. Remove and clean the spark plug if necessary.

18 914-0113 (Issue 3)

4 Maintenance

4.1 Maintenance Schedule

Periodic maintenance is essential for top performance. Use the table below as a guide. Under
hot or dusty operating conditions, some maintenance operations should be performed more
frequently, as indicated by the footnotes in the table.

Keep a log of maintenance performed and the hours run. Recording maintenance will help you
keep it regular and provide a basis for supporting warranty claims. A Maintenance Record form
is included at the back of this manual.

WARNING: Accidental starting of the generator set during maintenance can cause

severe personal injury or death. Before performing maintenance, disconnect
the spark plug wire from the spark plug. For electric start models, disconnect
both of the generator set starting battery cables. To reduce the risk of arcing,
remove the negative (–) cable first and reconnect it last.

WARNING: Contact with a hot generator set can cause severe burns. Always allow the

generator set to cool before performing any maintenance or service.

TABLE 3. PERIODIC MAINTENANCE SCHEDULE

SERVICE INTERVAL

SERVICE THESE ITEMS

General Inspection X

Check Oil Level X

Change Engine Oil X X

Clean Air Filter X

Clean Cylinder Cooling Fins X

Clean Spark Plug X

Clean the Spark Arrestor X

Clean Fuel Sediment Cup X

Clean Fuel Tank X

Adjust Valve Lash X

Check fuel line Every 2 years (Replace if necessary)

EACH EVERY

USE MONTH

1

FIRST EVERY 3 EVERY 6 EVERY

MONTH OR MONTHS OR MONTHS OR YEAR OR

20 HOURS 50 HOURS 100 HOURS 300 HOURS

2

2

3

1. See General Inspections.

2. Service more frequently when used in dusty environments.

3. These items must be performed by a trained and experienced mechanic (A list of authorized Cummins Onan

dealers is available at www.cumminsonan.com).

3

3

3

914-0113 (Issue 3) 19

4. Maintenance 8-2009

4.2 General Inspections

The operator should check the following before the first start of the day and after every eight
hours of operation:

1. Look for fuel leaks around the fuel tank, fuel hose, fuel valve, and carburetor. Close the
fuel valve and repair leaks immediately.

2. Look and listen for exhaust leaks while the engine is running. Have all leaks repaired
before continuing operation.

WARNING: Contact with a hot generator set can cause severe burns. Always allow the

generator set to cool before performing any maintenance or service.

3. Check for dirt and debris and clean as necessary.

CAUTION: A clogged flywheel air inlet screen or dirty cooling fins can cause overheating and

engine damage. Keep the cooling fins and air inlet screen clean.

4. Check the engine oil level and add oil as necessary. See Changing Engine Oil.

4.3 Changing Engine Oil

WARNING: State and federal agencies have determined that contact with used engine oil

can cause cancer and reproductive toxicity. Avoid skin contact and breathing
of vapors. Use rubber gloves and wash exposed skin.

Refer to the Periodic Maintenance Schedule Table in the Maintenance Schedule section for
scheduled oil changes and Figure 8.

1. Make sure the generator set is level and has been run until warm.

WARNING: Crankcase pressure can blow hot engine oil out of the fill opening, causing

severe burns. Always stop the generator set before removing the oil fill cap.

2. Stop the generator set and remove the oil fill cap (see Figure 8).

3. Remove the oil drain plug and drain the oil into a pan.

4. Reinstall the drain plug and refill with new engine oil just to the brim of the fill opening. Use
the oil fill tube provided with the generator to fill oil. See Engine Oil Recommendations
for the type of engine oil to use and Specifications for engine oil capacity.

CAUTION: Too little oil can cause severe engine damage. Make sure that the oil level is above

the Add mark on the dipstick.

5. Start the generator set and let it run for a short time while checking for oil leaks.

6. Used oil is harmful to the environment. Pour the used oil into a sealed container and
deliver it to the nearest recycling center.

20 914-0113 (Issue 3)

8-2009 4. Maintenance

No. Description No. Description

1 Oil Filler Cap 4 Upper Level

2 Oil Drain Bolt 5 Lower Level

3 Oil Fill Tube

FIGURE 8. OIL CHECK, FILL, AND DRAIN

4.4 Air Filter Maintenance

Refer to the Maintenance Schedule for scheduled air filter maintenance. Clean more often in
dusty environments.

CAUTION: A dirty air cleaner restricts air flow to the carburetor. To prevent carburetor

malfunction, service the air cleaner regularly. Service more frequently when
operating the generator set in extremely dusty areas.

WARNING: Using gasoline or flammable solvents to clean components can cause a fire

or explosion, which can result in severe personal injury or death. Only use
soapy water or a nonflammable solvent for cleaning components.

CAUTION: Running the engine without an air cleaner causes rapid engine wear. Never run the

engine without the air cleaner installed.

1. Remove the filter cover (Item 2 in Figure 9) by unsnapping the two spring clips (Item 1).

2. Remove the two foam filter elements (Item 3) and thoroughly wash them with soap and
water. Let them dry thoroughly.

3. Knead in 1 teaspoon (5 cm3) of clean engine oil into each foam filter element. The oil
should be distributed evenly throughout each filter element.

4. Reinstall the filter elements, the gray filter first (finer pores), and then the black filter (larger
pores).

914-0113 (Issue 3) 21

4. Maintenance 8-2009

5. Secure the cover with the spring clips.

No. Description No. Description

1 Clip 3 Air Filter Element

2 Air Filter Cover

FIGURE 9. AIR FILTER

4.5 Fuel Sediment Cup Cleaning

Refer to the Maintenance Schedule section for scheduled cleaning. Have the filter replaced if
the fuel has been contaminated or the engine seems to have lost power. Cleaning and
replacement must only be performed by an authorized Cummins Onan dealer.

4.6 Spark Plug Maintenance

Refer to the Maintenance Schedule section for scheduled spark plug maintenance. Perform
spark plug maintenance sooner if engine performance has deteriorated. To ensure proper
engine operation, the spark plug must be properly gapped and free of deposits. A fouled spark
plug can cause the engine to misfire, operate erratically, or stop running when a load is applied.

WARNING: Contact with hot generator parts can cause severe burns. Always allow the

generator set to cool before performing any maintenance or service.

1. Turn off the generator set and allow it to cool down.

2. Remove the spark plug cap.

3. Clean any dirt from around the spark plug base.

4. Use the wrench supplied in the tool kit to remove the spark plug.

5. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped. If the spark
plug is to be reused, clean it with a wire brush.

22 914-0113 (Issue 3)

8-2009 4. Maintenance

6. Measure the plug gap with a feeler gauge. Correct as necessary by carefully bending the
side electrode. The gap should be 0.70-0.80mm (0.028-0.031 inch).

7. Verify that that the spark plug washer is in good condition. Thread the spark plug in by
hand to prevent cross-threading.

8. After the spark plug is seated, tighten with a spark plug wrench to compress the washer. If
installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the
washer. If reinstalling a used spark plug, tighten 1/8-1/4 turn after the spark plug seats to
compress the washer.

No. Description No. Description

1 Removed Spark Plug Boot 2 Plug Wrench

FIGURE 10. SPARK PLUG REMOVAL

No. Description No. Description

1 Side Electrode 2 Metal Brush

FIGURE 11. SPARK PLUG MAINTENANCE

914-0113 (Issue 3) 23

4. Maintenance 8-2009

4.7 Cleaning the Generator Set

Refer to the Maintenance Schedule section for scheduled cleaning of the generator set. Clean
more often in dusty environments. Remove spilled oil and fuel from the generator set
immediately with a dry rag. Dispose of cleaning rags properly. Use a damp cloth to clean dust
and dirt from the generator set. Do not use cleaning solvents, which can damage electrical
components.

WARNING: Wear safety glasses to protect your eyes from flying debris when cleaning

the generator set with compressed air.

CAUTION: Cleaning the generator set with a pressure washer can cause damage to the

generator set by shorting the generator and other electrical components. Do not
use a pressure washer to clean the generator set.

Wear safety glasses if using compressed air to clean the engine cooling fins. Do not use a
pressure washer to clean the generator set. Water can enter the generator and other electrical
components causing shorts that can disable the generator set.

4.8 Cleaning the Spark Arrester

WARNING: Contact with a hot muffler can cause severe burns. Allow the generator set to

cool before servicing the muffler.

Refer to the Maintenance Schedule for scheduled spark arrester cleaning.

After letting the generator set cool down, remove the spark arrester screen. Inspect for damage
and replace if defective. To clean, lightly tap the screen and clean any deposits with a wire
brush. Reinstall the spark arrester and tighten the screw securely.

24 914-0113 (Issue 3)

8-2009 4. Maintenance

No. Description

1 Spark Arrestor

FIGURE 12. SPARK ARRESTOR

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4. Maintenance 8-2009

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26 914-0113 (Issue 3)

5 Troubleshooting

The following troubleshooting guide can be used for basic problem diagnosis. If these
recommendations do not resolve the problem, contact an authorized Cummins Onan service
center.

WARNING: Many troubleshooting procedures or replacement of parts present hazards

that can result in equipment damage or severe personal injury or death. Only
trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform service procedures.
Review the Safety Precautions section of this manual.

WARNING: Contact with a hot generator set can cause severe burns. Always allow the

generator set to cool before performing any maintenance or service.

ENGINE WON'T START

Logic: The generator set will not start.

Possible Causes:

· Out of fuel

· Fuel value closed

· Loose spark plug cable

· Defective spark plug

· Low oil level

Corrective Action:

1. Make sure the fuel tank is full.

2. Make sure the fuel valve is fully open.

3. Make sure the spark plug cable is connected.

4. Remove and clean the spark plug; replace it if necessary.

5. Check the oil level and add oil as necessary.

6. If the problem is still not corrected, contact a Cummins Onan service center.

BLACK EXHAUST

Logic: The exhaust is dark.

Possible Causes:

· Choke stuck in the closed position

· Dirty air cleaner

· Rich fuel mixture

Corrective Action:

1. Make sure the choke is open.

2. Clean the air cleaner.

3. If the problem is still not corrected, contact a Cummins Onan service center for information
on fuel mixtures.

914-0113 (Issue 3) 27

5. Troubleshooting 8-2009

WARNING: Many troubleshooting procedures or replacement of parts present hazards

that can result in equipment damage or severe personal injury or death. Only
trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform service procedures.
Review the Safety Precautions section of this manual.

WARNING: Contact with a hot generator set can cause severe burns. Always allow the

generator set to cool before performing any maintenance or service.

ENGINE STOPS

Logic: The generator set stops on its own.

Possible Causes:

· Out of fuel

· Low oil level

Corrective Action:

1. Make sure the fuel tank is full.

2. Check the oil level and add oil as necessary.

3. If the problem is still not corrected, contact a Cummins Onan service center.

ENGINE SURGES

Logic: The engine suddenly runs faster than normal.

Possible Causes:

· Loose spark plug cable

· Faulty spark plug

· Generator set not level

· Dirty fuel strainer

Corrective Action:

1. Make sure the spark plug cable is properly connected or have it serviced, if damaged.

2. Remove and clean or replace the spark plug.

3. Make sure the generator set is on a level surface.

4. Check the fuel strainer and clean if necesary.

5. If the problem is still not corrected, contact a Cummins Onan service center.

28 914-0113 (Issue 3)

8-2009 5. Troubleshooting

WARNING: Many troubleshooting procedures or replacement of parts present hazards

that can result in equipment damage or severe personal injury or death. Only
trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform service procedures.
Review the Safety Precautions section of this manual.

WARNING: Contact with a hot generator set can cause severe burns. Always allow the

generator set to cool before performing any maintenance or service.

NO AC OUTPUT

Logic: The generator set is running but you are not able to operate any tools or appliances.

Possible Causes:

· Tripped AC circuit breaker

Corrective Action:

1. Remove all loads.

2. Reset the circuit breaker.

3. Check loads for defects and make sure the total load does not exceed the generator set
rating.

4. If the problem is still not corrected, contact a Cummins Onan service center.

NO DC OUTPUT

Logic: The engine will not crank.

Possible Causes:

· Tripped DC circuit breaker

Corrective Action:

1. Disconnect the battery.

2. Reset the circuit breaker.

3. Have the battery tested for shorts and, if necessary, replace the battery.

4. If the problem is still not corrected, contact a Cummins Onan service center.

914-0113 (Issue 3) 29

5. Troubleshooting 8-2009

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30 914-0113 (Issue 3)

6 Specifications

TABLE 4. EGMBR (P2200) AND EGMBS (P2600) SPECIFICATIONS

GENERATOR EGMBR (P2200) EGMBS (P2600)

AC OUTPUT:

Frequency (Hertz) 50 Hz 50 Hz

Voltage 230 Volts 230 Volts

Rated Power 2000 Watts 2500 Watts

Rated Current 8.7 Amps 10.9 Amps

DC OUTPUT: 12 VDC / 8.3 Amps 12 VDC / 8.3 Amps

ENGINE

Engine Speed
(RPM)

Fuel Gasoline Gasoline

Engine Oil
Capacity*

Spark Plug Type F7RTC F7RTC

Spark Plug Gap 0.028 in. (0.7 mm) 0.028 in. (0.7 mm)

Engine Valve Lash
(Intake /
Exhaust)

Ignition Timing
(Fixed)

Starting System Recoil Recoil

Displacement 196 cc 196 cc

GENERATOR SET

Dry Weight 100 lbs (45 kg) 106 lbs (48 kg)

Dimensions:

Length 24.1 inches (612 mm) 24.1 inches (612 mm)

Width 19.6 inches (497 mm) 19.6 inches (497 mm)

Height 19.3 inches (490 mm) 19.3 inches (490 mm)

Fuel Tank Capacity 4 US Gal (15 L) 4 US Gal (15 L)

Operating Time at
Rated Output

* See Engine Oil Recommendations for recommended engine oil type.

0.004 / 0.006 inches 0.004 / 0.006 inches

3000 3000

0.63 US qt (0.6 L) 0.63 US qt (0.6 L)

(0.10 / 0.15 mm) (0.10 / 0.15 mm)

20° BTDC 20° BTDC

13 Hours 13 Hours

914-0113 (Issue 3) 31

6. Specifications 8-2009

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32 914-0113 (Issue 3)

7 Maintenance Record

Record all periodic and unscheduled maintenance and service. Refer to the Maintenance
section of this manual.

DATE HOURS RUN MAINTENANCE OR SERVICE PERFORMED

Record the name, address, and phone number of your authorized Cummins Onan service
center.

914-0113 (Issue 3) 33

7. Maintenance Record 8-2009

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34 914-0113 (Issue 3)

8 Global Addresses

EUROPE, MIDDLE EAST AND Latin America ASIA PACIFIC
AFRICA

Cummins Power Generation Limited Cummins Power Generation Limited Cummins Power Generation Limited
Unit 1 Stevern Way Reynolds R. Jati, 310-Guarulhos 31 Maxwell Road Pooraka, South

Industrial Park, Peterborough Australia Post Code 5095
PE15EL, UK

Phone [phone] Phone [phone] Phone [phone]

Sao Paulo-Brasil
CEP 07180-900

Fax [phone]

914-0113 (Issue 3) 35

8. Global Addresses 8-2009

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36 914-0113 (Issue 3)

Cummins Power Generation

1400 73rd Ave. NE
Minneapolis, MN 55432 USA

Phone [phone]
Toll-free 1 800 888 6626
Fax [phone]
Email www.cumminsonan.com/contact
www.cumminsonan.com

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

E2009 Cummins Power Generation, Inc. All rights reserved.