CUMMINS EGMBR (P2200), P2600, EGMBR, EGMBS Service Manual

Service Manual

Portable Generator Set

EGMBR, P2200 (Spec A)

EGMBS, P2600 (Spec A)

English 10−2009 914−0507 (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 Wheel Kit.................................................................................................................................. 7

2.4 Fuel Requirements................................................................................................................... 7

2.5 Generator Set Assembly Instructions ...................................................................................... 8

2.6 Wheel Kit Assembly Instructions ............................................................................................. 8

3. HOW TO OBTAIN SERVICE ........................................................................................................ 11

3.1 Outside North America........................................................................................................... 11

3.2 Information to Have Ready .................................................................................................... 11

4. STARTING AND RUNNING THE GENERATOR SET.................................................................. 13

4.1 Control Panel ......................................................................................................................... 13

4.2 Specifications......................................................................................................................... 13

4.3 Pre-Start Checks.................................................................................................................... 14

4.4 Starting the Generator Set..................................................................................................... 16

4.5 Stopping the Generator Set ................................................................................................... 18

4.6 Powering Tools and Appliances ............................................................................................ 18

4.7 Charging Batteries ................................................................................................................. 20

4.8 Circuit Breakers ..................................................................................................................... 20

4.9 Grounding .............................................................................................................................. 21

4.10 Low Oil Shutdown ................................................................................................................ 21

4.11 Electrical Interference with Communications or Appliances ................................................ 21

4.12 Exercising the Generator Set............................................................................................... 21

4.13 Engine Break-In ................................................................................................................... 22

4.14 Out-of-Service Protection..................................................................................................... 22

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Table of Contents 10-2009

5. GENERATOR COMPONENTS..................................................................................................... 26

6. SPECIFICATIONS ........................................................................................................................ 29

7. DIMENSIONS AND TORQUES .................................................................................................... 31

7.1 Engine Dimensions ................................................................................................................ 31

7.2 Generator Dimensions ........................................................................................................... 32

7.3 Torque Specifications ............................................................................................................ 33

7.4 Standard Torque Specifications............................................................................................. 33

8. MAINTENANCE ............................................................................................................................ 35

8.1 Maintenance Schedule .......................................................................................................... 35

8.2 General Inspections ............................................................................................................... 36

8.3 Engine Oil .............................................................................................................................. 36

8.4 Air Filter Maintenance............................................................................................................ 38

8.5 Fuel Sediment Cup Cleaning................................................................................................. 39

8.6 Cleaning the Spark Arrester .................................................................................................. 40

8.7 Valve Clearance..................................................................................................................... 41

8.8 Governor Adjustments ........................................................................................................... 42

9. SERVICING THE GENERATOR SET .......................................................................................... 45

9.1 Preparing for Service ............................................................................................................. 45

10. CONTROL PANEL....................................................................................................................... 49

10.1 Control Panel Components.................................................................................................. 49

10.2 Control Panel Service .......................................................................................................... 50

11. GENERATOR SERVICE ............................................................................................................. 59

11.1 Generator Disassembly ....................................................................................................... 59

11.2 Generator Reassembly ........................................................................................................ 62

11.3 Brush Block and Slip Rings ................................................................................................ 62

11.4 Generator Component Testing ............................................................................................ 63

12. ENGINE ....................................................................................................................................... 67

12.1 Cylinder Head / Valves ........................................................................................................ 67

12.2 Camshaft/Crankshaft ........................................................................................................... 73

12.3 Piston ................................................................................................................................... 78

12.4 Oil Level Switch ................................................................................................................... 83

13. FUEL, START, AND IGNITION SYSTEMS ................................................................................. 85

13.1 Fuel System ......................................................................................................................... 85

13.2 Choke Assembly .................................................................................................................. 88

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10-2009 Table of Contents

13.3 Governor Assembly ............................................................................................................. 89

13.4 Carburetor............................................................................................................................ 91

13.5 Fuel Cut-Off Solenoid .......................................................................................................... 93

13.6 Starting System.................................................................................................................... 93

13.7 Ignition System .................................................................................................................... 97

13.8 Cooling Fan and Fan Cover............................................................................................... 103

13.9 Flywheel............................................................................................................................. 104

14. INTAKE / EXHAUST SYSTEM .................................................................................................. 107

14.1 Muffler ................................................................................................................................ 108

14.2 Air Cleaner ......................................................................................................................... 109

15. TROUBLESHOOTING............................................................................................................... 113

15.1 Engine Won't Crank (Manual Start) ................................................................................... 113

15.2 Engine Cranks But Won't Start .......................................................................................... 113

15.3 Engine Starts But Stops Suddenly..................................................................................... 114

15.4 Unstable Speed ................................................................................................................. 114

15.5 Abnormal Exhaust Color .................................................................................................... 115

15.6 Low Engine Speed............................................................................................................. 116

15.7 Low Power ......................................................................................................................... 116

15.8 No DC Output Voltage ....................................................................................................... 117

15.9 No AC Output Voltage ....................................................................................................... 118

16. SERVICE CHECKLIST .............................................................................................................. 119

16.1 Mounting ............................................................................................................................ 120

16.2 Lubrication ......................................................................................................................... 120

16.3 Wiring................................................................................................................................. 120

16.4 Initial Start Adjustments ..................................................................................................... 120

16.5 Exhaust System ................................................................................................................. 121

16.6 Fuel System ....................................................................................................................... 121

16.7 Output Check ..................................................................................................................... 121

16.8 Control ............................................................................................................................... 121

16.9 Mechanical......................................................................................................................... 121

17. WIRING DIAGRAMS ................................................................................................................. 124

17.1 Wiring Diagram of P2200/P2600 ....................................................................................... 125

18. MAINTENANCE RECORD ........................................................................................................ 127

19. GLOBAL ADDRESSES ............................................................................................................. 129

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iv 914-0507 (Issue 4)

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.

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1. Safety Precautions 10-2009

· 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.

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10-2009 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.

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1. Safety Precautions 10-2009

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4 914-0507 (Issue 4)

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.

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 personnel 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

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2. Introduction 10-2009

No. Description No. Description

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10-2009 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 Wheel Kit

The assembled wheel kit shown below is optional equipment.

FIGURE 3. WHEEL KIT INSTALLED

2.4 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.

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2. Introduction 10-2009

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-producting equipment, and all other sources of ignition well away from
the area.

2.5 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. If necessary, install the wheel kit (see the Wheel Kit Assembly Instructions).

3. Add oil to the generator set (see Engine Oil Recommendations).

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

the Add mark on the dipstick.

4. 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.

2.6 Wheel Kit Assembly Instructions

CAUTION: Improper handling of the generator set can result in equipment damage. Do not

turn the generator set on the side, top, or end. Doing so may damage the
generator set or cause dangerous fuel or oil leakage. Do not place items on top of
the generator set. The wheel kit is designed to support the generator only.

Required Tools

· 10 and 12 mm wrenches, sockets, and ratchet

· Three 6-inch high blocks of wood

· Pliers

Installation Procedure

1. Install the handle assembly (handle, bracket, hinge pin, grips, end plugs, two cotter pins,
and fasteners).

a. Use two long bolts to attach the handle assembly to the frame.

b. Tighten securely; do not crush the frame tube.

2. Block up the generator set under both frame tubes as shown below. Place a block under
the center of the cross-member on the exhaust end.

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10-2009 2. Introduction

3. Install the leg assembly.

a. Install a leg assembly (support leg, rubber pad, and fastener) onto each side of the

exhaust end cross-member.

b. Use two bolts and nuts for each leg and tighten securely.

4. Install the wheel and axle assembly (axle assembly and wheel assemblies).

a. Remove the rubber pads secured to the frame where the axle is attached.

b. Remove the cotter pins and loose washers from the axle assembly (axle, two loose

washers, two cotter pins, and fasteners).

c. Install the wheels (flat free tire and wheel); make sure the long hub is to the inside.

d. Reinstall the washers and cotter pins on the axle assembly. Bend one leg of each

cotter pin.

e. Place the axle assembly under the cross member as shown and install four bolts and

nuts. Tighten securely.

No. Description No. Description

1 Frame 4 Support Leg Assembly

2 Wheel Assembly 5 Wooden Blocks

3 Axle Assembly 6 Handle Assembly

FIGURE 4. INSTALLED WHEEL KIT

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2. Introduction 10-2009

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10 914-0507 (Issue 4)

3 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.

3.1 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].

3.2 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.

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12 914-0507 (Issue 4)

4 Starting and Running the Generator

Set

4.1 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 Two Schuko Outlets (230V, 16A)

3 AC Circuit Breaker Reset 6 Voltmeter

7 DC Breaker

FIGURE 5. CONTROL PANEL

4.2 Specifications

TABLE 1. EGMBR (P2200) & EGMBS (P2600) SPECIFICATIONS

GENERATOR EGMBR (P2200) EGMBS (P2600)

AC OUTPUT:

Frequency (Hertz) 50 Hz 50 Hz

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4. Starting and Running the Generator Set 10-2009

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 12VDC/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 197 cc 196 cc

GENERATOR SET

Dry Weight 99.2 lbs (45 kg) 105.8 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 (Non-CARB Models) 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 Recommendationsfor recommended engine oil type.

0.006 / 0.008 inches 0.006 / 0.008 inches

3000 3000

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

(0.15 / 0.20 mm) (0.15 / 0.20 mm)

20° BTDC 20° BTDC

13 Hours 13 Hours

4.3 Pre-Start Checks

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

CAN KILL QUICKLY.

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

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10-2009 4. Starting and Running the Generator Set

· 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.

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.

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4. Starting and Running the Generator Set 10-2009

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.

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.

4.4 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 6).

2. Pull the choke rod out to close the choke if the engine is cold (see Figure 7).

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 8).

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.

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10-2009 4. Starting and Running the Generator Set

FIGURE 6. FUEL VALVE

No. Description No. Description

1 Choke Lever 3 Closed

2 Open

FIGURE 7. CHOKE ROD

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4. Starting and Running the Generator Set 10-2009

FIGURE 8. RECOIL START HANDLE

4.5 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 servere

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

4.6 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.

4.6.1 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

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10-2009 4. Starting and Running the Generator Set

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.

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4. Starting and Running the Generator Set 10-2009

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.

4.6.2 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.

4.7 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.

4.8 Circuit Breakers

FIGURE 9. AC AND DC 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.

20 914-0507 (Issue 4)

10-2009 4. Starting and Running the Generator Set

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 manufacurer's
instructions and warnings regarding use, maintenance, and proper
grounding.

4.9 Grounding

FIGURE 10. EARTH GROUND LUG

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.

4.10 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.

4.11 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.

4.12 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.

914-0507 (Issue 4) 21

4. Starting and Running the Generator Set 10-2009

4.13 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.

4.14 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.

4.14.1 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 11).

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.

22 914-0507 (Issue 4)

10-2009 4. Starting and Running the Generator Set

No. Description

1 Fuel Drain Bolt

FIGURE 11. CARBURETOR DRAIN

4.14.2 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.

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.

914-0507 (Issue 4) 23

4. Starting and Running the Generator Set 10-2009

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24 914-0507 (Issue 4)

914-0507 (Issue 4) 25

5. Generator Components 10-2009

5 Generator Components

26 914-0507 (Issue 4)

10-2009 5. Generator Components

No. Description No. Description

1 Fuel Tank Cap 8 12 Volt DC Terminals

2 Fuel Gauge 9 2 Type1/Australian 15A/240V outlets

3 Choke Lever 10 Earth Ground Lug

914-0507 (Issue 4) 27

5. Generator Components 10-2009

4 Fuel Valve 11 AC Breaker Reset Switch

5 Air Cleaner 12 DC Breaker Reset Switch

6 Recoil Starter Grip 13 Muffler

7 On / Off Switch 14 Spark Plug Boot

FIGURE 12. COMPONENTS

28 914-0507 (Issue 4)

6 Specifications

TABLE 3. 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

914-0507 (Issue 4) 29

6. Specifications 10-2009

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30 914-0507 (Issue 4)

7 Dimensions and Torques

7.1 Engine Dimensions

TABLE 4. DIMENSIONS AND TORQUES FOR PORTABLE GENERATOR SETS

Part Item Factory Specification

Maximum Speed 3180 ±150 rpm -

Engine

Cylinder Sleeve I.D.

Cylinder
Head

Piston Piston Pin Bore I.D.

Idle Speed 1400 ±150 rpm -

Cylinder Compression -

Warpage -

Skirt O.D.

Piston-to-Cylinder Clearance

Pin O.D.

Piston-to-Piston Pin Bore Clearance

Ring Side Clearance Top/Second/Oil

6.0-8.5 kg/cm2(85.4 –

121 lbs/in2) at 600 rpm

68.015 mm 68.165 mm
(2.6778 in) (2.6837 in)

67.985 mm 67.845 mm
(2.6766 in) (2.6711 in)

0.030 - 0.050 mm 0.12 mm

(0.0012 - 0.0020 in) (0.005 in)

18.002 mm 18.048 mm
(0.7087 in) (0.7105 in)

17.998 mm 17.954 mm
(0.7086 in) (0.7068 in)

0.004 - 0.016mm 0.06 mm

(0.00016 - 0.0006 in) (0.002 in)

0.015 - 0.045 mm 0.15 mm

(0.0006 - 0.0018 in) (0.0006 in)

Allowable

Limit

0.10 mm

(0.004 in)

Top/Second 0.2 - 0.4 mm 1.0 mm

Oil (0.008 - 0.016 in) (0.04 in)

Top/Second

Oil

1.5 mm 1.37 mm

(0.06 in) (0.054 in)

2.5 mm 2.37 mm

(0.10 in) (0.093 in)

18.007 mm 18.07 mm
(0.7089 in) (0.711 in)

30.015 mm
(1.1817 in)

0.030 0.050 mm 0.12 mm

(0.0012 - 0.0020 in) (0.0048 in)

0.1 - 0.7 mm 1.1 mm

(0.004-0.028 in) (0.043 in)

30.0667
mm

(1.1837 in)

Piston Rings

Connecting
Rod

Ring End Gap

Ring Width

Small End I.D. (Pin End)

Big End I.D. (Crankshaft)

Big End Oil Clearance

Big End Side Clearance

914-0507 (Issue 4) 31

7. Dimensions and Torques 10-2009

Crankshaft Crankshaft O.D. (Connecting Rod Large End)

IN -

Valve Lash

EX -

IN

Stem O.D.

EX

Valves Guide I.D. IN/EX

IN

Stem Clearance

EX

Seat Wdith

Spring Free Length

IN

Cam Height

Camshaft EX

Camshaft O.D.

Crankcase
Cover

Spark Plug Gap -

Ignition Coil

Camshaft-Bearing I.D.

Primary Coil 0.8 - 1.0 Ω -

Resistance

Secondary Coil 5.9 - 7.1 KΩ -

Air Gap (At Flywheel) -

29.985 mm 29.92 mm
(1.181 in) (1.178 in)

0.10 ±0.02 mm

(0.004 ±0.001 in)

0.15 ±0.02 mm

(0.006 ±0.001 in)

5.48 mm 5.318 mm

(0.216 in) (0.2094 in)

5.47 mm 5.275 mm

(0.215 in) (0.2077 in)

5.50 mm 5.572 mm

(0.217 in) (0.2194 in)

0.02 - 0.044 mm 0.10 mm

(0.0008 - 0.0017 in) (0.004 in)

0.06 - 0.087 mm 0.12 mm

(0.0024 - 0.0034 in) (0.005 in)

0.8 mm 2.0 mm

(0.03 in) (0.08 in)

30.0 mm 28.5 mm
(1.18 in) (1.122 in)

27.7 mm 27.45 mm
(1.09 in) (1.081 in)

27.75 mm 27.5 mm
(1.093 in) (1.083 in)

13.984 mm 13.916 mm
(0.5506 in) (0.5479 in)

14.0 mm 14.048 mm
(0.55 in) (0.5531 in)

0.7 - 0.8 mm

(0.028 - 0.031 in)

0.4 ±0.2 mm

(0.016 ±0.008 in)

7.2 Generator Dimensions

TABLE 5. DIMENSIONS FOR EGMBR (P2200) 2.0 KW GENERATORS

Part Item Factory Specification

Main winding (R / Bu) Resistance 0.60 - 0.72 Ω

Field winding Resistance 33 - 41 Ω

Exciter winding (Bu / Bu) Resistance 3.756 - 4.556 Ω

DC Winding (G / G) Resistance 0.172 - 0.212 Ω

32 914-0507 (Issue 4)

10-2009 7. Dimensions and Torques

Carbon brush Brush length 5-9 mm

TABLE 6. DIMENSIONS FOR EGMBS (P2600) 2.5 KW GENERATORS

Part Item Factory Specification

Main winding I (Br / W) Resistance 0.43 - 0.53 Ω

Field winding Resistance 40 - 48 Ω

Exciter winding (Bu / Bu) Resistance 4.23 - 5.23 Ω

DC winding (G / G) Resistance 0.169 - 0.209 Ω

Carbon brush Brush length 5 - 9 mm

7.3 Torque Specifications

Part Fastener Size Torque Values N·m (kg·cm, ft·lb)

Cylinder head bolt 8×1.25×55 mm 26-28 (260 - 280, 18.8 - 20.2)

Pivot bolt 6×0.5 mm 8 - 12 (80 - 120, 5.8 - 8.7)

Pivot adjusting nut 6×1.25 mm 22 - 26 (220 - 260, 15.9 - 18.8)

Crankcase cover bolt 8×1.25×32 mm 24 - 26 (240 - 260, 17.4 - 18.8)

Connecting rod bolt 7×1.25 mm 12 - 14 (120 - 140, 8.7 - 17.4)

Air cleaner wing nut 6×1.0 mm 7 - 10 (70 - 100, 5.1 - 7.2)

Air cleaner mounting nut 6×1.0 mm 7 - 10 (70 - 100, 5.1 - 7.2)

Muffler mounting bolt 8×1.25 mm 20 - 28 (200 - 280, 14.5 - 20.2)

Oil drain bolt 10×1.5 mm 20 - 25 (200 - 250, 14.5 - 18.1)

Fuel tank mounting bolt/ nut 6×1.0 mm 8 - 12 (80 - 120, 5.8 - 8.7)

Fuel valve joint nut 10×1.25 mm 20 - 25 (200 - 250, 14.5 - 18.1)

Oil level switch mounting nut 10×1.25 mm 8 - 12 (80 - 120, 5.8 - 8.7)

Flywheel mounting nut 14×1.25 mm 80 - 90 (800 - 900, 58 - 865.3)

7.4 Standard Torque Specifications

Standard torque values 5 mm bolt, nut 4 - 7 (40 - 70, 2.9 - 5.1)

6 mm bolt, nut 8 - 12 (80 - 120, 5.8 - 8.7)

8 mm bolt, nut 20 - 28 (200 - 280, 14.5 - 20.2)

10 mm bolt, nut 35 - 40 (350 - 400, 14.5 - 20.2)

12 mm bolt, nut 50 - 60 (500 - 600, 36.2 - 43.4)

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7. Dimensions and Torques 10-2009

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34 914-0507 (Issue 4)

8 Maintenance

8.1 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 shut down

the generator set and allow it to cool before performing any maintenance or
service.

TABLE 7. PERIODIC MAINTENANCE SCHEDULE

SERVICE INTERVAL

SERVICE THESE ITEMS

General Inspection X

Check Oil Level X

Test GFCI 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

3

3

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).

914-0507 (Issue 4) 35

8. Maintenance 10-2009

8.2 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.

8.3 Engine Oil

8.3.1 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 8. 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

8.3.2 Checking Engine Oil Level

Check the oil level BEFORE EACH USE with the generator set on a level surface and with the
engine stopped.

1. Remove the oil filter cap the wipe the dipstick clean.

2. Check the oil level by inserting the dipstick into the filler neck without screwing it in.

3. If the level is low, add enough of the recommended oil so that oil level is at the upper mark
on the dipstick.

36 914-0507 (Issue 4)

10-2009 8. Maintenance

WARNING: Used motor oil may cause skin cancer if repeatedly left in contact with the

skin for prolonged periods. Thoroughly wash your hands with soap and
water as soon as possible after handling used oil.

8.3.3 Changing Engine Oil

NOTE: Drain the oil while the engine is still warm to assure rapid and complete

draining.

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.

1. Remove the oil fill cap and drain plug.

2. Drain the oil from the crankcase.

3. Reinstall the drain plug securely.

4. Add new oil up to the bottom edge of the oil fill hole with the engine stopped and in a level
position.

5. Reinstall the oil fill cap and tighten it securely.

Engine Oil Capacity = 1.16 US quart (1.1 liters).

Recommended Engine Oil: SAE 10W30 is recommended for general, all temperature use:
American Petroleum Institute (API) SG - SF/CC - CD.

No. Description No. Description

1 Oil Filler Cap 4 Upper Level

2 Oil Drain Bolt 5 Lower Level

3 Oil Fill Tube

FIGURE 13. OIL CHECK, FIL, AND DRAIN

914-0507 (Issue 4) 37

8. Maintenance 10-2009

FIGURE 14. OIL VISCOSITY VS. TEMPERATURE

WARNING: Used motor oil may cause skin cancer if repeatedly left in contact with the

skin for prolonged periods. Thoroughly wash your hands with soap and
water as soon as possible after handling used oil.

8.4 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 15) 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).

5. Secure the cover with the spring clips.

38 914-0507 (Issue 4)

10-2009 8. Maintenance

No. Description No. Description

1 Clip 3 Air Filter Element

2 Air Filter Cover

FIGURE 15. AIR FILTER

8.5 Fuel Sediment Cup Cleaning

The sediment cup prevents dirt or water which may be in the fuel tank from entering the
carburetor. If the engine has not been run for a long time, the sediment cup should be cleaned.
Refer to the Maintenance Schedulefor scheduled fuel sediment cup cleaning.

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-producting equipment, and all other sources of ignition well away from
the area.

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

personal injury or death. After reassembly, check for leaks and make sure
the area is dry before starting the engine.

1. Turn the fuel valve to the OFF position. Remove the sediment cup, and o-ring.

2. Clean the sediment cup and o-ring in a nonflammable or high flash-point solvent.

3. Reinstall the o-ring and sediment cup.

4. Turn the fuel valve ON and check for leaks.

914-0507 (Issue 4) 39

8. Maintenance 10-2009

No. Description No. Description

1 Fuel Valve 3 Fuel Filter

2 Sediment Cup (10 mm) 4 O-Ring

FIGURE 16. FUEL SEDIMENT CUP COMPONENTS

8.6 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.

40 914-0507 (Issue 4)

10-2009 8. Maintenance

No. Description

1 Spark Arrestor

FIGURE 17. SPARK ARRESTOR

8.7 Valve Clearance

Refer to the Maintenance Schedule for scheduled valve clearance adjustment.

CAUTION: Valve clearance inspection and adjustment must be performed with the engine

cold.

1. Remove the valve cover, and set the piston at top dead center of the compression stroke
(both valves fully closed).

2. Insert a feeler gauge between the rocker arm and valve to measure valve clearance. The
recommended valve clearance is shown below.

Standard Valve Clearance

3. If adjustment is necessary, proceed as follows:

IN

EX

0.15 ±0.02 mm

(0.006 ±0.001 in)

0.20 ±0.02 mm

(0.008 ±0.001 in)

a. Hold the rocker arm pivot and loosen the pivot lock nut.

b. Turn the rocker arm pivot to obtain the specified clearance.

c. Retighten the lock nut while holding the rocker arm pivot.

914-0507 (Issue 4) 41

8. Maintenance 10-2009

d. Recheck valve clearance after tightening the lock nut.

No. Description No. Description

1 Rocket Arm 3 Pivot

2 Lock Nut (10-14 Nm)

To increase valve clearance, screw lock nut out.
To decrease valve clearance, screw lock nut in.

FIGURE 18. VALVE COMPONENTS

FIGURE 19. VALVE ADJUSTMENT WITH FEELER GAUGE INSTALLED

8.8 Governor Adjustments

1. Remove the fuel tank.

2. Loosen the nut on the governor arm pinch bolt.

42 914-0507 (Issue 4)

10-2009 8. Maintenance

3. Move the arm until the throttle is completely open, and hold it in that position.

4. Rotate the governor arm shaft as far as it will go in same direction it was just moved by the
governor arm, and then tighten the governor arm pinch bolt.

5. Check to see if the arm and throttle move smoothly.

6. Reinstall the fuel tank.

7. Start the engine and let it warm up. Once the engine is warm, adjust the limiting screw to
set the idle speed.

The idle speed should be set to 3600 ±150 RPM.

No. Description No. Description

1 Governor Nut Spring 5 Limiting Screw

2 Governor Arm Shaft 6 Anti-Surge Spring

3 Governor Arm Pinch Bolt 7 Governor Arm

4 Throttle 8 Nut

FIGURE 20. GOVERNOR ASSEMBLY

914-0507 (Issue 4) 43

8. Maintenance 10-2009

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44 914-0507 (Issue 4)

9 Servicing the Generator Set

9.1 Preparing for Service

9.1.1 Safety Considerations

There are hazards in servicing generator sets. Study the Safety Precautions section of this
manual and become familiar with the hazards listed in Table 9. Note the following safeguards
and ways of avoiding hazards.

· Use personal protection: Wear appropriate protective safety equipment, such as safety
shoes and safety glasses.

· Do not wear rings or jewelry and do not wear loose or damp clothing that might get caught
in equipment or conduct electricity.

· Reduce the hazard: A safe, orderly workshop area, and well-maintained equipment
reduce the hazard potential. Keep guards and shields in place on machinery and maintain
equipment in good working condition. Store flammable liquids in approved containers;
away form fire, flame, spark, pilot light, switches, arc-producing equipment, and other
ignition sources. Keep the workshop clean and well-lighted and provide adequate
ventilation.

· Develop safe work habits: Unsafe actions cause accidents with tools and machines. Be
familiar with the equipment and know how to use them safely. Use the correct tool for the
job and check its condition before starting. Comply with the warnings in this manual and
take special precautions when working around electrical equipment. Do not work alone if
possible and take no risks.

· Be prepared for an accident: Keep fire extinguishers and safety equipment nearby.

Fire and Explosion

Burns

Poisonous Gas

Agencies such as the Red Cross and public safety departments offer courses in first aid,
CPR and fire control. Take advantage of this information to be ready to respond to an
accident. Learn to be safety-conscious and make safety procedures part of the work
routine.

TABLE 9. HAZARDS AND THEIR SOURCES

· Leaking or spilled fuel

· Hydrogen gas from battery

· Oily rag improperly stored

· Flammable liquids improperly stored

· Hot exhaust pipes

· Hot engine and generator surfaces

· Operating generator set where exhaust gases can accumulate

914-0507 (Issue 4) 45

9. Servicing the Generator Set 10-2009

· Improper generator connections

Electrical Shock (AC)

Rotating Machinery

Slippery Surfaces

Heavy Objects

· Faulty wiring

· Working in damp conditions

· Jewelry touching electrical components

· Fan guards not in place

· Leaking or spilled oil

· Removing the generator set from the vehicle

· Removing heavy components

9.1.2 Special Tools

Engine:

A complete set of standard and metric shop tools are required to service the engine.

Control and Generator:

A complete set of standard and metric shop tools are required to service the control and
generator. Also needed are:

· Lead or dead blow hammer

· Battery hydrometer

· Torque wrench

· VOM meter

· Frequency meter

· Armature growler

· Load bank

· Jumper wires

· Rotor puller

9.1.3 Removal and Replacement of Gaskets

The following is a list of portable generator sets that may have been built with gaskets that
contain some percentage of asbestos.

· All 60 Hz Cummins Onan branded HomeSite Power portable generator sets built before
January 1, 2008 - Models 5EGMBE, 4EGMBD, 2.5EGMBG, 2EGMBB

· All 50 hz Cummins branded portable generator sets built before November 1, 2008 -
Models 5EGMBU, 4EGMBT, 2EGMBR, 2.5EGMBS

The manufactured date can be determined from the product serial number located on the unit's
nameplate (see the figure below). The first alpha character represents the month the unit was
manufactured (A = January, B = February through L = December). The second and third digits
represent the year the unit was manufactured. In the example shown below, the generator set
was manufactured in November of 2005.

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10-2009 9. Servicing the Generator Set

FIGURE 21. PORTABLE GENERATOR SET NAMEPLATE

OSHA (USA) classifies the removal and handling of these gaskets as "Class III" asbestos work,
which is the lowest OSHA category of activity that is considered likely to disturb
asbestos-containing material. OSHA has established the following precautions for Class III
asbestos work.

· Product Repair Instructions: The normal operation of generators subject to this
communication does not require any additional precautions. However, when performing
any repair involving a gasketed joint, to ensure the safe removal and handling of the
gasket, 1) the gasket must be wetted down and, 2) if available, local exhaust and
ventilation systems must be used.

· The used gasket(s) should then be disposed of by following all local rules and regulations
regarding the disposal of hazardous materials.

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48 914-0507 (Issue 4)

10 Control Panel

The control panel is the direct point of interface for the operation of the generator set. It contains
the receptacles, circuit breakers and switches required for safe customer load connections.

This section includes information on the following:

· Control panel components

· Control panel service

10.1 Control Panel Components

The following is a description of components included on the control panel of portable generator
sets. Please note that not all of the components listed below are on all control panels.

10.1.1 Engine Switch (Manual Start)

To start the generator, move the switch to the Run position. To turn off the generator, move the
switch to the Off position.

10.1.2 DC Terminals

The DC terminals are the point of connection for DC loads. The DC terminals provide 12 VDC
with a peak current of 8.3 Amps.

10.1.3 DC Breaker

The DC breaker protects the DC load connections and the generator from DC electrical faults.
The breaker is set to trip at 8.3 Amps.

10.1.4 L14-30 Receptacle

The L14-30 receptacle is a circular four-prong electrical outlet. It provides 240 VAC, 60 Hz.

10.1.5 AC Circuit Breakers

The AC circuit breakers provide electrical protection to both the generator set and the
connected loads. Each circuit breaker is connected to the outlet situated directly below the
breaker. The load rating of each breaker can be seen below each breakers corresponding
outlet.

10.1.6 Diodes

The diodes are located within the control panel assembly. The diodes rectify AC power into DC
power to be used by the DC terminals.

10.1.7 Voltmeter

The voltmeter displays the output voltage of the generator set on an analog scale.

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10. Control Panel 10-2009

10.1.8 Voltage Selector Switch

The generator can produce either 120 or 240 VAC, based on the position of the voltage selector
switch. When in the 120 VAC position, only the GFCI and the L5-30 receptacle provides power
at 120 VAC, 60 Hz. When the voltage selector switch is set to the 120/240 VAC position, the
L14-30 provides 240 VAC, 60 Hz at full load. In the 120/240 VAC position, the 120 VAC
receptacles can only provide half the load. Between all three receptacles, the total sum of all
loads cannot exceed the generator power rating.

10.1.9 Ground Connection

The ground connection provides a point to connect an earthen terminated ground to protect the
user from ground faults.

10.2 Control Panel Service

10.2.1 Control Panel Removal

Removal of the control panel is shown in the following figure.

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10-2009 10. Control Panel

No. Description No. Description

1 Fuel Cutoff Solenoid Lead 3 Control Panel

2 On / Off Switch 4 Generator End Cover

FIGURE 22. CONTROL PANEL REMOVAL

To remove the control panel,

1. Remove the two bolts on each side of the control panel to disconnect the control panel
from the frame.

2. Disconnect the lead connecting the engine ground.

3. Disconnect the fuel cut-off solenoid, the oil alert system, and the field winding.

4. To disconnect the control panel from the start solenoid, first unplug the ground connection.
Then unscrew the nut holding on the positive lead.

5. Remove the two bolts on the end cap to remove the end cap.

6. Disconnect the DC coupler and field winding coupler. Unscrew the bolt holding the
couplers in place.

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10. Control Panel 10-2009

7. Unscrew the nuts holding the main winding leads and disconnect them.

10.2.2 Control Panel Installation

Reassembly if the control panel is the reverse of removal.

1. Reconnect the main winding leads and secure them with nuts.

2. Connect the DC coupler and field winding coupler. Use a bolt to secure them in place.

3. Use two bolts to secure the end cap.

4. Use a nut to secure the positive lead to the start solenoid and then plug in the ground
connection.

5. Connect the fuel cut-Off solenoid, the oil alert system, and the field winding.

6. Connect the lead connecting the engine ground .

7. Use two bolts to secure each side of the control panel to the frame.

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10.2.3 Control Panel Internal Components for 50Hz

No. Description No. Description

1 On / Off Switch AC Breaker Reset Switches 5 AC Receptacle (240VAC)

2 DC Breaker Reset Switch 6 Earth Ground Lug

3 Voltmeter 7 DC Terminals (12V)

4 AC Breaker Reset Switch 8 Panel Front Cover

FIGURE 23. CONTROL PANEL COMPONENTS

To gain access to the control panel internal components,

1. Follow the steps described in Control Panel Removal.

2. Remove the back panel from the control panel assembly by removing the eight nuts
holding it in place (7 mm).

3. Remove the two rubber grommets on the back of the control panel to allow for the cables
to slide through, and the back panel to be removed.

10.2.3.1 Receptacles

To test and/or replace a receptacle,

1. Disconnect the leads to the receptacle.

2. Remove the receptacle from the control panel by unscrewing the connection while holding
the locking nut in place.

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10. Control Panel 10-2009

3. To reinstall a receptacle, install the receptacle on the control panel, secure with the locking
nuts, and reconnect the leads.

10.2.3.2 Diodes

To test and/or replace a diode,

1. Disconnect the leads to the diode.

2. Remove the screw passing through the center of the diode.

3. To reinstall a diode, use the screw to secure it to the control panel and reconnect the
leads.

10.2.3.3 Circuit Breakers

To test and/or replace a circuit breaker,

1. Disconnect the leads to the circuit breaker.

2. Unscrew the nut on the front of the control panel while holding the circuit breaker in place.
Then remove the circuit breaker.

3. To reinstall a circuit breaker, use the screw to secure it to the control panel and reconnect
the leads.

10.2.3.4 Ground Connection

1. Remove the nut on the back of the ground connection to disconnect the leads.

2. Remove the nut on the back of the ground connection to remove it from the control panel.

3. Reassemble in the reverse order.

10.2.3.5 Voltmeter

NOTE: A voltmeter is not available on all models.

To test and/or replace the voltmeter,

1. Remove the nuts connecting the leads to the back of the voltmeter.

2. Remove the four nuts holding the voltmeter in place and remove the voltmeter from the
control panel.

3. Reverse this procedure to install the voltmeter.

10.2.3.6 Voltage Selector Switch

To remove and replace the voltage selector switch,

1. Disconnect the leads from the voltage selector switch.

2. The switch is held in place by two metal brackets. Press these brackets away from the
switch to remove the switch.

3. To reinstall, first make sure the brackets are seated properly, and then press the switch
firmly into place. Make sure that the switch locks into both brackets and then reconnect the
leads.

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10.2.3.7 DC Terminals

To remove and reinstall the DC terminals,

1. Remove the nuts connecting the leads to the DC terminals.

2. Remove the nuts holding the DC terminals in place.

3. To reinstall the DC terminals, use the nuts to secure the DC terminals and then reconnect
the leads to the DC terminals.

10.2.3.8 Start / Stop Switch

To remove and install the Start / Stop Switch,

1. Disconnect the leads from the Start / Stop Switch.

2. The switch is held in place by two metal brackets. Press these brackets away from the
switch to remove the switch.

3. To reinstall, first make sure the brackets are seated properly, and then press the switch
firmly into place. Make sure that the switch locks into both brackets and then reconnect the
leads.

10.2.4 Control Panel Component Testing

10.2.4.1 Engine Switch

Check for continuity between the terminals with the switch in each position.

The engine switch includes the following connection wires:

· IG - Yellow/Black

· E - Black

· FS - Green/White

· G - Green/White

· L - Red

· L - White

When the switch is set to the “OFF” position, IG is connecting to E. When the switch is set to
the “ON” position, L is connecting to L.

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10. Control Panel 10-2009

FIGURE 24. ENGINE ON / OFF SWITCH

10.2.4.2 DC Breaker Reset Switch

Check continuity between the breaker terminals.

There should be continuity with the breaker button pushed in.

FIGURE 25. DC BREAKER RESET SWITCHES

10.2.4.3 AC Breaker Reset Switches

Check continuity between the breaker terminals.

There should be continuity with the breaker button pushed in.

FIGURE 26. AC BREAKER RESET SWITCHES

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10.2.4.4 Voltmeter

Using an ohmmeter, check for continuity between the terminals.

Continuity should exist between them.

FIGURE 27. VOLTMETER

10.2.4.5 AC Receptacle

1. Disconnect the wires from the back of the receptacle.

2. Connect the terminals on the front of the receptacle using a piece of wire.

3. Using an ohmmeter, check for continuity between the terminals.

4. If there is no continuity, the receptacle is defective, and must be replaced.

10.2.4.6 Fuse

FIGURE 28. AC RECEPTACLE

There should be continuity between the terminals.

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10. Control Panel 10-2009

FIGURE 29. FUSE

10.2.4.7 Voltage Selector Switch

Using an ohmmeter, check for continuity between the pins as shown, with the switch wires
unplugged.

· When voltage selector switch to “120” position, 4 is connecting to 1, 5 is connecting to 2
and 6 is connecting to 3.

· When voltage selector switch to “240” position, 1 is connecting to 7, 2 is connecting 8 and
3 is connecting to 9.

FIGURE 30. VOLTAGE SELECTOR SWITCH CONNECTIONS

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11 Generator Service

Generator service includes the following:

· Disassembling and assembling the generator

· Examining the brush block and slip rings

· Testing the generator

11.1 Generator Disassembly

1. Place a brace block underneath the alternator.

2. Remove the two bolts on the end cap to remove the end cap.

3. Disconnect the DC coupler and field winding coupler. Unscrew the bolt holding the
couplers in place.

4. Unscrew the nuts holding the main winding leads and disconnect them.

5. Remove the bolt holding the field windings and disconnect the connector.

6. Remove the brush block assembly.

7. Remove the voltage regulator.

8. Remove the muffler mounting bracket.

9. Remove the ground wire from the top of the alternator assembly.

10. Remove the alternator cooling fan shroud.

11. Remove the rotor through bolt (item 4).

12. Remove the nuts securing the alternator to the vibration isolators (item 6).

13. Remove the four bolts on the outside of the generator connecting the alternator to the
engine adaptor.

14. Carefully remove the stator assembly from the generator adaptor.

CAUTION: To avoid damaging the rotor, place a wooden block and a shop rag under the rotor

for support.

15. Use a rotor puller to remove the rotor. When removing the rotor, hold the flywheel and
torque the puller to 6.9 Kg-cm (50 ft-lbs).

NOTE: If torquing the rotor puller does not free the rotor from the crankshaft, tap the

end of the puller with a brass hammer to help loosen the rotor.

WARNING: Contact with sharp or moving parts can cause severe personal injury or

death. To prevent eye injury, always wear safety glasses or goggles when
striking the end of the rotor puller.

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11. Generator Service 10-2009

No. Description No. Description

1 Crankcase Grommet 4 Rotor Bolt

2 Generator Assembly 5 Stator Bolt

3 Brush Holder Assembly 6 Rubber Mount

FIGURE 31. GENERATOR REMOVAL

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No. Description No. Description

1 Rear Housing 6 Ball Bearing

2 Generator Cooling Fan 7 Generator End Cover

3 Stator Cover 8 AVR Assembly

4 Stator 9 Brush Holder Assembly

5 Rotor 10 AC Output Terminal

FIGURE 32. REAR HOUSING COMPONENTS

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11. Generator Service 10-2009

11.2 Generator Reassembly

To reassemble the generator,

1. Wipe dirt and oil off the tapered portion of the rotor and crankshaft.

2. Install the stator assembly on the generator adapter.

3. Make sure the crankcase grommet is inserted securely.

4. Use four stator bolts to install the alternator on the engine adapter. Do not tighten the bolts
yet.

5. Use the nuts to install the alternator on the vibration isolators.

6. Tighten the stator bolts in a crisscross pattern. Torque the stator bolts to 8-12 N·m (5.8-8.7
ft-lbs). Make sure there is no clearance between the crankcase cover and the stator cover.

7. Install the washer and rotor through bolt. Torque the through bolt to 43-47 N·m (31.0-33.9
ft-lbs).

8. Install the alternator cooling fan shroud.

9. Install the ground wire on the top of the alternator assembly.

10. Install the muffler mounting bracket.

11. Install the voltage regulator.

12. Install the brush block assembly.

13. Use a bolt to install the field windings and connect the connector.

14. Connect the main winding leads and use the nuts to secure them.

15. Connect the DC coupler and the field winding coupler. Secure the couplers.

16. Install the end cap and secure it with two bolts.

11.3 Brush Block and Slip Rings

FIGURE 33. BRUSH HOLDER ASSEMBLY

1. To remove the brush block, remove the end cap and the brush block mounting screw.
Then remove the brush block from the generator end bell.

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2. Check the brush for length, wearing condition, or any other defect. Replace if the length is
less than 5 mm (0.20 in).

NOTE: Connect the blue wire lead to the positive (+) side of the brush holder. Avoid

damaging the brushes when removing and installing the brush holder.

3. Visually inspect the slip rings for dust, rust or other damage. If necessary, wipe them with a
clean lint-free cloth. If they are rusted or damaged, remove the rotor and rub with fine
emery cloth.

11.4 Generator Component Testing

11.4.1 Field Winding

Remove the brushes and measure resistance between the slip rings.

RESISTANCE P2200 33-41 Ω

P2600 40-48 Ω

Slip Ring - END µ

If the specified resistance is obtained at the slip rings but not at the brush terminals, clean or
replace the brushes.

If the specified resistance is not obtained at the slip rings, clean or replace the rotor.

FIGURE 34. MEASURING FIELD WINDING RESISTANCE

11.4.2 Main Winding

1. Using an ohmmeter, measure the resistance between the AC output terminals.

RESISTANCE P2200 0.60-0.72 Ω

P2600 0.43-0.53 Ω

NOTE: Set the voltage selector switch to 120 V only position.

2. If the resistance is out of specification, replace the stator.

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11. Generator Service 10-2009

FIGURE 35. AC OUTPUT TERMINALS

11.4.3 Exciter Winding

1. Using an ohmmeter, measure the resistance between the Blue and Blue wires in the 4P
coupler.

RESISTANCE P2200 3.756-4.556 Ω

P2600 4.23-5.23 Ω

Slip Ring - Ground µ

2. If the resistance is out of specification, replace the stator.

FIGURE 36. MEASURING EXCITER WINDING RESISTANCE

11.4.4 DC Winding

1. Using an ohmmeter, measure the resistance between the brown wire leads at the DC
diode connecter.

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2. The resistance should be 0.17-0.21 Ω. If the resistance is out of specification, replace the
stator.

FIGURE 37. MEASURING DC WINDING RESISTANCE

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12 Engine

This section includes information on service the engine, including:

· Cylinder head/valves

· Camshaft/crankshaft

· Piston

12.1 Cylinder Head / Valves

12.1.1 Disassembly / Reassembly

To disassemble the cylinder head and valves,

1. To remove the cylinder head, the carburetor, exhaust manifold, and all preceeding
components must be removed.

2. Remove the breather tube and valve cover. Use solvent to clean any oil from the breather
valve.

3. Loosen the cylinder head bolts and the cylinder head cover bolts using a crisscross
pattern, and remove the cylinder head.

CAUTION: Removing the valve spring retainers while the cylinder head is installed will cause

the valves to drop into the cylinder which can result in equipment damage. Do not
remove the valve spring retainers while the cylinder head is installed.

4. Compress the valve spring and slide the retainer out to the side, so that the valve stem
slips through the hole at the side of the retainer.

5. After the valves are removed, check both ends for wear and check the rod for straightness.
Make sure the rod ends are firmly seated in the lifter.

6. Remove the rocker arms by removing the rocker lock and pivot nuts.

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12. Engine 10-2009

No. Description No. Description

1 Cylinder Head Cover 7 Dowel Pin

2 Cylinder Head Bolt 8 Crankcase

3 Spark Plug 9 Stud

4 Muffler Gasket 10 Cylinder Head Cover Gasket

5 Stud 11 Breather Hose

6 Cylinder Head Gasket 12 Cylinder Head Cover Bolts

FIGURE 38. CYLINDER HEAD REMOVAL

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No. Description No. Description

1 Valve RotatorValve Rocket Arm 7 Intake Valve

2 Valve Spring Retainer 8 Cylinder Head

3 Valve Spring 9 Push Rod

4 Spark Plug 10 Pushrod Guide

5 Cylinder Head Bolt 11 Rocker Arm Pivot Stud

6 Exhaust Valve 12 Rocker Arm

FIGURE 39. CYLINDER HEAD COMPONENTS

To reassemble the cylinder head and valves,

1. Before reassembly, remove carbon deposits from the cylinder head combustion changer
and inspect the valve seats.

Valve Head Diameter: (IN = 24 mm (0.94 in), EX = 22 mm (0.87 in).

2. When reinstalling the valves, make sure that you do not interchange the intake valve with
the exhaust valve.

CAUTION: If the valve rotator is not installed correctly, the valve may drop into the cylinder

when starting the engine, resulting in engine damage. Always make sure the valve
rotator is properly installed.

3. Before reinstalling the rocker arms, check the pivot bolts, push rods, and rocker arms.
Remove all carbon deposits from the push rods and inspect the valve.

4. Note the installation direction of the cylinder head cover gasket before installing it.

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12. Engine 10-2009

5. Reinstall the cylinder head. Torque the cylinder head bolts to 26-28 N·m (260-280 kg·cm,

18.7-20.2 ft·lb) using a crisscross pattern.

6. Reinstall the cylinder head cover. Torque the cylinder head cover bolts to 12-14 N·m
(120-140 kg·cm, 8.7-17.4 ft·lb).

7. After reassembly, measure the compression of the cylinder head.

8. Before reinstalling the spark plug, clean and adjust as necessary.

12.1.2 Cylinder Head Inspection

TABLE 10. CYLINDER HEAD

No. Description No. Description

1 Straight Edge 2 Feeler Gauge

1. Remove carbon deposits from the combustion chamber. Clean off any gasket material
from the cylinder head surface.

2. Check the spark plug hole and valve areas for cracks.

3. Use a straight edge and a feeler gauge to check the cylinder head for flatness. The
allowable limit is 0.1 mm (0.004 in).

TABLE 11. VALVE SEAT WIDTH

Factory Specification Allowable Limit

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0.8 mm (0.03 in) 2.0 mm (0.08 in)

1. Measure the valve seat width.

2. If the valve seat width is under the factory specification or over the service limit, recondition
the valve seat.

TABLE 12. VALVE GUIDE INSIDE DIAMETER

Factory Specification Allowable Limit

5.50 mm (0.217 in) 5.572 mm (0.2194 in)

NOTE: Ream the valve guides to remove any carbon deposits before measuring.

1. Measure and record each valve guide inside diameter.

2. Replace the cylinder head if it is over the allowable limit.

TABLE 13. GUIDE TO STEM CLEARANCE

Factory Specification Allowable Limit

IN 0.02-0.044 mm (0.0008-0.0017 in) 0.10 mm (0.004 in)

EX 0.06-0.087 mm (0.0024-0.0034 in) 0.12 mm (0.005 in)

The guide to stem clearance is determined by subtracting each valve stem outside diameter
from the corresponding guide inside diameter.

If the stem to guide clearance exceeds the allowable limit, determine if a new guide with
standard dimensions would bring the clearance within tolerance. If so, replace any guide as
necessary and ream to fit. If the stem to guide clearance exceeds the allowable limit with new
guides, replace the valves as well.

NOTE: Whenever the valve guides are replaced, be sure to recondition the valve

seats.

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12. Engine 10-2009

TABLE 14. VALVE STEM OUTSIDE DIAMETER

Factory Specification Allowable Limit

IN 5.48 mm (0.216 in) 5.318 mm (0.2094 in)

EX 5.47 mm (0.215 in) 5.275 mm (0.2077 in)

1. Inspect each valve for face irregularities, bending, or abnormal stem wear. Replace the
valve if necessary. Measure and record each valve stem outside diameter.

2. Replace the valves if their outside diameter is smaller than the allowable limit.

TABLE 15. VALVE SPRING FREE LENGTH

Factory Specification Allowable Limit

30.0 mm (1.18 in) 28.5 mm (1.122 in)

1. Measure the free length of the valve springs.

2. Replace the springs if they are shorter than the allowable limit.

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12.2 Camshaft/Crankshaft

No. Description No. Description

1 Piston 7 Oil Dipper

2 Piston Triangle Mark 8 Crankshaft

3 Oil Alert Unit 9 Camshaft

4 Oil Level Switch 10 Tappets

5 Oil Seal 11 Decompressor Weight

6 Radial Ball Bearing

FIGURE 40. ENGINE COMPONENTS

Disassembly:

1. To gain access to the internal crankcase components, the generator and all preceeding
components must be removed.

2. Remove the bolts securing the crankcase cover.

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12. Engine 10-2009

3. Gently tap the crankcase cover with a plastic hammer to loosen and remove the cover.

4. Remove the camshaft first.

5. To remove the crankshaft, the piston and flywheel must first be removed.

No. Description No. Description

1 Crankshaft 3 Camshaft

2 Index Marks

FIGURE 41. CAMSHAFT/CRANKSHAFT MARKINGS

Reassembly,

1. Push the camshaft (Item 8) in until the bearing touches the crankcase. Be careful not to
damage the oil seal.

2. Reinstall the piston (item 1).

3. Install the tappets (item 10) immediately before installing the camshaft (item 9).

4. When reinstalling the camshaft, make sure the decompressor weight (item 11) moves
smoothly and the spring is not weak or worn.

5. Align the index marks on the camshaft with the index mark on the crankshaft (see Figure

41).

6. Reinstall the crankcase cover.

7. Reinstall the bolts and torque to spec, using a crisscross pattern.

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12.2.1 Camshaft / Crankshaft Inspection

TABLE 16. CRANKSHAFT OUTSIDE DIAMETER

Factory Specification Allowable Limit

29.985 mm (1.181 in) 29.92 mm (1.178 in)

TABLE 17. CONNECTING ROD LARGE END SIDE CLEARANCE

Factory Specification Allowable Limit

0.1 - 0.7 mm (0.004 - 0.028 in) 1.1 mm (0.043 in)

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TABLE 18. CAMSHAFT HEIGHT

Factory Specification Allowable Limit

IN 27.7 mm (1.09 in) 27.45 mm (1.081 in)

EX 27.75 mm (1.093 in) 27.50 mm (1.083 in)

TABLE 19. CAMSHAFT OUTSIDE DIAMETER

Factory Specification Allowable Limit

13.984 mm (0.5506 in) 13.916 mm (0.5479 in)

TABLE 20. CRANKCASE COVER - CAMSHAFT HOLDER INSIDE DIAMETER

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Factory Specification Allowable Limit

14.00 mm (0.55 in) 14.048 mm (0.5531 in)

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12.3 Piston

No. Description No. Description

1 Marking 5 Piston Pin Clip

2 Piston 6 Oil Ring

3 Piston Pin 7 Second Ring

4 Connecting Rod 8 Top Ring (Chrome Plated)

FIGURE 42. PISTON ASSEMBLY

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Disassembly:

1. To remove the piston, the cylinder head and crankcase cover must be removed.

2. Remove the connecting rod cap.

Reassembly:

1. Install all rings with the markings facing upward.

2. Make sure that the top (chrome plated) ring (item 8) and the second ring (item 7) are not
interchanged.

3. Once installed, make sure that the rings rotate smoothly.

4. Space the piston ring end gaps 120 degrees apart. Do not align the gaps with the piston
pin bore.

5. Install the connecting rod with the long end toward the triangle marked side of the piston.

6. Install the piston pin clip (item 5) by setting one end of the clip in the piston grove, holding
the other end with long-nosed pliers, and rotating the clip in. Do not align the end gap of
the clip with the cut-out in the piston pin bore.

7. When reinstalling the piston into the cylinder (item 1) make sure the triangle mark (item 2)
is facing the push rods.

8. Install the oil dipper (item 7) toward the camshaft. The ribs on the cap and the connecting
rod must be aligned.

12.3.1 Piston Inspection

TABLE 21. CYLINDER SLEEVE INSIDE DIAMETER

Factory Specification Allowable Limit

68.015 mm (2.6778 in) 68.165 mm (2.6837 in)

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TABLE 22. PISTON SKIRT OUTSIDE DIAMETER

Factory Specification Allowable Limit

67.985 mm (2.6766 in) 67.845 mm (2.6711 in)

TABLE 23. PISTON-TO-CYLINDER CLEARANCE

Factory Specification Allowable Limit

0.03 - 0.05 mm (0.0012 - 0.002 in) 0.12 mm (0.005 in)

TABLE 24. PISTON RING SIDE CLEARANCE

Factory Specification Allowable Limit

0.030 - 0.060 mm (0.0012-0.0024 in) 0.15 mm (0.006 in)

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TABLE 25. PISTON RING END GAP

Factory Specification Allowable Limit

0.2 - 0.4 mm (0.008 - 0.016 in) 1.0 mm (0.04 in)

TABLE 26. PISTON PIN OUTSIDE DIAMETER

Factory Specification Allowable Limit

17.998 mm (0.7086 in) 17.954 mm (0.7068 in)

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TABLE 27. PISTON PIN BORE INSIDE DIAMETER

Factory Specification Allowable Limit

18.002 mm (0.7087 in) 18.048 mm (0.7105 in)

TABLE 28. PISTON-TO-PISTON PIN BORE CLEARANCE

Factory Specification Allowable Limit

0.004 - .016 mm (0.00016 - 0.0006 in) 0.06 mm (0.002 in)

TABLE 29. CONNECTING ROD SMALL END INSIDE DIAMETER

Factory Specification Allowable Limit

18.006 mm (0.7089 in) 18.07 mm (0.711 in)

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TABLE 30. CONNECTION ROD LARGE END INSIDE DIAMETER

Factory Specification Allowable Limit

30.015 mm (1.1817 in) 30.066 mm (1.1837 in)

12.4 Oil Level Switch

Check continuity of the switch with an ohmmeter.

1. Hold the switch in its normal position. The ohmmeter should read zero resistance.

2. Hold the switch upside down. The ohmmeter should read infinity (∞) resistance.

3. Inspect the float by dipping the switch into a container of oil. The ohmmeter reading should
go from zero to infinity as the switch is lowered.

No. Description No. Description

1 Off 2 On

FIGURE 43. CHECKING OIL LEVEL SWITCH CONTINUITY

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13 Fuel, Start, and Ignition Systems

13.1 Fuel System

This section includes information on servicing the fuel system, including:

· The fuel tank

· The choke assembly

· The governor assembly

· The carburetor

· The fuel cut-off solenoid

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13.1.1 Fuel Tank Removal

No. Description No. Description

1 Fuel Meter Assembly 5 Sediment Cup

2 Tank Cushion 6 Fuel Tank

3 Fuel Filter 7 Fuel Strainer

4 Fuel Check Valve 8 Fuel Tank Cap

FIGURE 44. FUEL TANK COMPONENTS

WARNING: Contact with a hot generator set can cause severe burns. Always shut down

the generator set and allow it to cool before performing any maintenance or
service.

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WARNING: Accidental starting of the generator set can cause severe personal injury or

death. Before performing maintenance, disconnect the spark plug wire from
the spark plug.

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

or death. Drain the fuel tank and fuel line before disassembly. Wipe up any
spilled fuel immediately.

To remove the fuel tank,

1. Make sure the generator set is turned off.

2. Disconnect the spark plug wire.

3. Drain the fuel from the fuel tank.

4. Close the fuel check valve (item 4).

5. Press the hose barb connecting the fuel line to the fuel check valve and remove the fuel
line.

6. Remove the four bolts and flat washers on the four corners of the fuel tank that are
securing the fuel tank to the fuel tank brackets.

7. Remove the brace located above the recoil by removing the two bolts holding the brace in
place.

8. Slide the fuel tank out of the recoil side of the frame.

13.1.2 Fuel Tank Service and Installation

To service the fuel tank,

1. Wash the tank externally and internally to remove any sediment and allow it to thoroughly
dry.

2. Remove the fuel tank cap, and fuel strainer.

a. Check to see if they are clean and undamaged. Replace if necessary.

b. Make sure that the air vent on the fuel tank cap is clean and unclogged. Blow with

compressed air if necessary.

c. Reinstall the fuel strainer, fuel tank cap, and seal.

3. Turn the tank over and remove the sediment cup, fuel valve, and fuel filter.

a. Check the fuel filter and make sure it is clean and unclogged. Replace if necessary.

b. Wash the sediment cup to remove sediment.

c. Check the fuel valve passages to make sure they are not clogged.

d. Reinstall the sediment cup, fuel valve, and fuel filter.

4. Slide the fuel tank into the recoil side of the frame.

5. Use the two bolts to secure the brace above the recoil.

6. Use the four bolts to secure the four corners of the fuel tank to the frame.

7. Reinstall the fuel line.

8. Open the fuel check valve.

9. Add fuel to the fuel tank.

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10. Check the operation of the fuel meter float to make sure an accurate level is being
displayed.

11. Reconnect the spark plug wire.

12. Start the generator set and let it run for a few minutes while checking for any fuel leaks at
the fuel connection points and at the fuel valve. If any leaks are detected, shut the
generator set off and repair as necessary.

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

personal injury or death. After reassembly, check for leaks and make sure
the area is dry before starting the engine.

13.2 Choke Assembly

The choke assembly is used to help a cold generator start. To start a cold generator, pull the
choke rod out into the start position. After starting the generator, push the choke rod back into
the run position.

No. Description No. Description

1 Choke Lever 3 Closed

2 Open

FIGURE 45. CHOKE ROD

13.2.1 Choke Assembly Removal

To remove the choke assembly,

1. Make sure the generator set is turned off.

2. Disconnect the spark plug wire.

3. Remove the air cleaner, as described in Air Cleaner Removal.

4. Remove the choke assembly.

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13.2.2 Choke Assembly Service and Installation

To service and reinstall the choke assembly,

1. Clean and inspect the choke assembly. Replace if necessary.

2. Reinstall the air cleaner as described in the Air Cleaner Service and Installation section.

13.3 Governor Assembly

The governor assembly regulates the speed of the generator by balancing the forces between
the governor gear and the governor spring. To adjust the governor, see the Governor

Adjustments section.

13.3.1 Governor Assembly Removal

No. Description No. Description

1 Governor Nut Spring 5 Limiting Screw

2 Governor Arm Pinch Bolt 6 Anti-Surge Spring

3 Governor Arm Shaft 7 Governor Arm

4 Throttle 8 Nut

FIGURE 46. GOVERNOR ASSEMBLY

To remove the governor assembly,

1. Remove the fuel tank, as described in the Fuel Tank Removal section.

2. Unlatch the anti-surge and governor springs (items 1 and 6).

3. Loosen the nut (item 8) holding the governor arm to the governor arm shaft.

4. Gently pull up on the governor arm (item 7) and remove it from the governor arm shaft
(item 3).

5. Remove the governor arm from the anti-surge spring arm.

6. Rotate the throttle (item 4) and slide the anti-surge spring arm up and out of the throttle.

7. Disconnect the anti-surge spring (item 6) from the throttle.

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8. Remove the three bolts securing the limiting screw bracket to the heat shielding and
remove the limiting screw bracket.

13.3.1.1 Governor Service and Installation

1. Clean and inspect the governor assembly. Replace any defective parts.

2. Secure the limiting screw bracket.

3. Connect the anti-surge spring to the throttle.

4. Install the anit-surge spring arm on the throttle.

5. Install the governor arm on the anti-surge spring arm.

6. Connect the governor arm to the governor arm shaft and secure it with a nut.

7. Install the anti-surge and governor springs.

8. Reinstall the fuel tank, as described in the Fuel Tank Service and Installation section.

9. Adjust the governor speed as necessary (refer to the Governor Adjustments section).

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13.4 Carburetor

No. Description No. Description

1 Pilot Screw 6 Drain Screw

2 Carburetor Body 7 Set Bolt

3 O-Ring 8 Float

4 Main Nozzle 9 Main Jet

5 Float Valve

FIGURE 47. CARBURETOR ASSEMBLY

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13.4.1 Carburetor Removal

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

personal injury or death. Close the fuel shutoff valve and drain the carburetor
before servicing the carburetor.

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

personal injury or death. Close the fuel shutoff valve and drain the carburetor
before servicing the carburetor.

To remove the carburetor,

1. Remove the air cleaner, choke assembly, and governor assembly. (Refer to the Air

Cleaner Removal, Choke Assembly Removal, and Governor Assembly Removal

sections.)

2. Close the shut-off valve and drain the carburetor.

3. Press the hose clamps and remove the fuel line.

4. Slide the carburetor back off the mounting bolts.

13.4.2 Carburetor Service and Installation

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

personal injury or death. Close the fuel shutoff valve and drain the carburetor
before servicing the carburetor.

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

personal injury or death. Close the fuel shutoff valve and drain the carburetor
before servicing the carburetor.

Before reassembly,

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

injury or death. Close the fuel shutoff valve and drain the carburetor before
servicing the carburetor.

· Use compressed air to clean the internal passages and orifices of the carburetor body.

· Check the pilot screw head for wear or damage. The initial opening of the screws is 1-5/8

turns out.

· Use compressed air to thoroughly clean the drain screw.

· Use compressed air to thoroughly clean the main jet.

· Use compressed air to thoroughly clean the main nozzle before installing it.

· Check to see if the float valve is worn or if the float valve spring is weak.

During reassembly,

· Check the O-ring for correct installation.

· Check the float for smooth operation once it is installed.

To install the carburetor,

1. Slide the carburetor back on the mounting bolts.

2. Use the hose clamps to reinstall the fuel line.

3. Reinstall the governor assembly, chock assembly, and air cleaner.

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4. Open the shut-off valve.

5. Check the drain screw for leaks and repair, if necessary.

6. Check the set bolt for sign of leakage and repair, if necessary.

13.5 Fuel Cut-Off Solenoid

The fuel cut-off solenoid prevents fuel from entering the engine when the generator set is not
operating. The fuel cut-off solenoid closes during shut down, starving the engine of fuel.

13.5.1 Fuel Cut-Off Solenoid Service

1. Disconnect the fuel cut-off solenoid leads from the control panel.

2. Remove the screws connecting the fuel cut-off solenoid to the carburetor.

3. Inspect the fuel cut-off solenoid for continuity between the double green wires and the
solenoid valve. If there is no continuity, replace the solenoid.

4. Use the two screws to reinstall the fuel cut-off solenoid to the carburetor.

5. Reconnect the fuel cut-off solenoid leads from the control panel.

13.6 Starting System

13.6.1 Recoil Starter

The recoil starter allows for the manual start of the generator and is available on all portable
models.

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No. Description No. Description

1 Recoil Drive Cup 4 Recoil Starter Assembly

2 Flange Nut 5 Cooling Fan

3 Fan Cover

FIGURE 48. RECOIL STARTER / FAN COVER ASSEMBLY

13.6.2 Recoil Starter Removal

WARNING: Contact with sharp or moving objects can cause severe personal injury.

Work carefully and wear protective safety glasses, gloves, and clothing when
working on the recoil starter due to the possibility of sharp flying objects and
rotating parts. Do not let the recoil spring snap.

1. Remove the three bolts on the front panel of the recoil assembly.

2. To gain access to the recoil ratchet and spring in the recoil starter assembly, carefully
remove the bolt on the reel cover (see the following figure).

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