CUMMINS EGMBL, PX4800, PX4800e, PX2900, PX3600 Operator's Manual

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Page 1

Operator Manual

50 Hz Commercial Portable Generator Set

EGMBL / PX4800

EGMBL / PX4800e

English 04−2008 914−0121 (Issue 2)

Page 2

For Parts Ordering and Technical Support

Please Contact

Cummins

50 – 52 Diagonal Road

Pooraka

South Australia 5082

Parts phone: 08 8368 4358

Service phone: 08 8368 4308

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

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CONTENTS

1. SAFETY PRECAUTIONS

・・・・・・・・・・・・・・・・4

2. SPECIFICATIONS

・・・・・・・・・・・・・・・・・・・6

3. COMPONENTS

・・・・・・・・・・・・・・・・・・・・

4. PRE-OPERATION CHECKS

・・・・・・・・・・・・・・・

5. OPERATING PROCEDURES

・・・・・・・・・・・・・・

6. WATTAGE INFORMATION

・・・・・・・・・・・・・・・

7. SPARK ARRESTER

・・・・・・・・・・・・・・・・・・2

8. MAINTENANCE SCHEDULE

・・・・・・・・・・・・・・

9. "HOW-TO" MAINTENANCE

・・・・・・・・・・・・・・・

10. PREPARATION FOR STORAGE

・・・・・・・・・・・・・

11. TROUBLESHOOTING

・・・・・・・・・・・・・・・・・

12. WIRING DIAGRAM

・・・・・・・・・・・・・・・・・・

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1. SAFETY PRECAUTIONS

ENGLISH

Please make sure you review each precaution carefully.

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

PX4800 & PX4800e - 4 - 11-06

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

WARNING

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

［

CAUTION

］

PX4800 & PX4800e - 5 - 11-06

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2. SPECIFICATIONS

ENGLISH

MODEL

Type

Starting system

L (U.S. gal)

mm (in.)

mL (cu.in.)

L (U.S. gal)

kg (lb)

hours

Model

Type

Voltage regulating system

VA (W)Rated output

AC Output

VA (W)

Maximum output

Rated voltage

Fuel tank capacity

hours

Engine oil capacity

Spark plug

Dry weight

Valve Clearance (Intake & Exhaust)

Emissions Durability Period (California only)

Specifications are subject to change without notice.

Displacement

ROBIN, Air-cooled, 4-stroke, OHC

211 (12.87)

Length

Width

Height

Recoil starter

Electric starter / Recoil

12.8 (3.37)

BR-6HS (NGK) (Champion; RL86C)

Rated continuous operation

0.6 (0.15)

Fuel Automotive Unleaded Gasoline

Fuse-less circuit breaker

Rated current

Safety device type

8.3

DC Output

Rated power factor 1.0

Condenser type

120/240-60120-60

PX3600 PX4800

PX2900

EX27D

EX17D

265 (16.17)169 (10.31)

Brush-less, self-exciting, 2-poles, single phase

V-Hz

Rated voltage-Frequency

Safety device type

Fuse-less circuit breaker

2900

3600

2400

2900

4100

4800

EX21D

650 (25.6)580 (22.8)

605 (23.8)

510 (20.1)420 (16.5)

450 (17.7)

540 (21.3)480 (18.9)

500 (19.7)

70 (154)48 (106)

54 (119)

0.12  mm (0.0047 in.)

Note : Adjust the valve clearance while the engine is cold.

)0.03 0

)0.0012 0

500

1.0 (0.26)

4.68.1

6.5

Engine Generator

Dimension

120/240-60

240-50

3500

4100

16.7

PX4800 & PX4800e - 6 - 11-06

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3. COMPONENTS

Fuel tank

Fuel gauge

Engine switch

Choke lever

Oil drain plug

Oil gauge (oil filler)

Spark plug cap

Air cleaner

Exhaust outlet

Tank cap

Fuel strainer (

Fuel cock

)

Muffler cover

Recoil starter

Recoil starter handle

Control panel

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ENGLISH

Engine switch

(PX4800 w/Starter motor)

Key switch

(PX2900)

AC receptacle 30A

Pilot lamp

Full power switch

AC receptacle 20A

AC receptacle 30A

DC output terminal

DC circuit breaker

AC protecter (RGX4800)

Earth(ground

)

terminal

Idel control switch

Earth(ground

)

terminal

AC circuit breaker

Hour meter

DC output terminal

DC circuit breaker

CONTROL PANEL

PX4800 & PX4800e - 8 - 11-06

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4. PRE-OPERATION CHECKS

Upper level

Oil filler cap (Oil gauge)

Lower level

CHECK ENGINE OIL

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

■

Remove oil filler cap and check the engine oil level.

■

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

■

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

Recommended engine oil :

Use 4-stroke automotive detergent oil of API service class SE or higher grade (SG, SH or SJ is recommended).

SAE

10W-30 or 10W-40 is recommended

for general, all-temperature use. If single viscosity oil is used, select the appropriate viscosity for the average temperature in your area.

Ambient temperature

Single grade

Multigrade

10W

20W

#20

#30

#40

10W

PX2900 . . . . . . . . . . . . . . 0.6 (0.15)

PX3600 . . . . . . . . . . . . . . 0.6 (0.15)

PX4800 . . . . . . . . . . . . . . 1.0 (0.26)

Oil capacity (Upper level) :

L (U.S. gal)

PX4800 & PX4800e - 9 - 11-06

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ENGLISH

■

Check fuel level at fuel level gauge.

■

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

■

Be sure to use the fuel filter screen on the fuel filter neck.

LEVEL

Fuel filter screen

Fuel tank cap

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

CHECK ENGINE FUEL.

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

■

Do not refill tank while engine is running or hot.

■

Close fuel cock before refueling with fuel.

■

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

■

Wipe off spilt fuel thoroughly before starting engine.

■

Keep open flames away.

WARNING

FULL

EMPTY

Fuel Amount

up to "LEVEL" position

12.8

liters

(3.37

U.S. gal

)

NOTE : THIS ENGINE IS CERTIFIED TO OPERATE ON AUTOMOTIVE UNLEADED GASOLINE.

PX4800 & PX4800e - 10 - 11-06

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CHECKING COMPONENT PARTS

Check following items before starting engine:

■

Fuel leakage from fuel hose, etc.

■

Bolts and nuts for looseness.

■

Components for damage or breakage.

■

Generator not resting on or against any adjacent wiring.

CHECK GENERATOR SURROUNDINGS

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

■

Keep area clear of in flammables or other hazardous materials.

■

Keep generator at least 3 feet (1 meter) away from buildings or other structures.

■

Only operate generator in a dry, well ventilated area.

■

Keep exhaust pipe clear of foreign objects.

■

Keep generator away from open flame. No smoking!

■

Keep generator on a stable and level surface.

■

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

WARNING

BATTERY INSTALLATION (PX4800 w/Electric Starter)

Recommended Battery

Type ; Lead-acid battery Capacity (Ah/5hr) ; 12V-21AH or more Size ; Less than 185(L) x 125(W) x 160(H) mm

Battery Base

Battery Frame

Fix to Frame

Fix to Frame Base

Bolt

Retainer

(+)

RED Cable

PX4800 & PX4800e - 11 - 11-06

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ENGLISH

GROUNDING THE GENERATOR

■

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

■

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

Grounding spike

Death, personal injury and/or property damage may occur unless instructions are followed carefully.

■

Use battery of recommended capacity.

■

Turn the starter switch to the "STOP" position when mounting or dismounting battery. When mounting battery, connect the positive (+) cable first and then the negative (

) cable to the battery. Be careful not to

short battery cables. When dismounting battery, disconnect negative (

)

cable first.

RED CABLE : To positive (+) terminal BLACK CABLE : To negative (

) terminal

■

Should the connection be made in incorrect manner, the generator will be broken.

■

Tighten bolts and nuts on terminals securely so they will not be loosened by vibration.

■

Disconnect battery cables when charging battery.

WARNING

PX4800 & PX4800e - 12 - 11-06

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5. OPERATING PROCEDURES

(a) Turn the Engine switch to the position

"ON".

(b) Turn the AC circuit breaker to the

position "OFF".

(d) Set choke lever to close if the engine

is cold.

STARTING THE GENERATOR

Check the oil level before each operations as outlined by the article "CHECK ENGINE OIL"

［

CAUTION

］

OFF

OPEN

Choke lever

OPEN

OFF

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ENGLISH

Pull briskly

(e) Pull the starter handle slowly until

passing the compression point (resistance will be felt), then return the handle to its original position and pull briskly.

■

If the engine fails to start after several attempts, repeat above procedures with choke lever returned to "OPEN" position.

■

Do not fully pull out the rope.

■

After starting, allow the starter handle to return to its original position while still holding the handle.

(f) After the engine started, return the

choke lever gradually to "OPEN" position.

Choke lever

OPEN

(g) Warm up the engine without a load for

a few minutes.

PX4800 & PX4800e - 14 - 11-06

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

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

appliance (s) before connecting to the generator.

appliance(s) into the receptacle.

(1) AC APPLICATION

USING ELECTRIC POWER

■

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

■

Do not move the generator while it is running.

■

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

WARNING

■

Check the amperage of the receptacles used referring to TABLE 1, and be sure not to take a current exceeding the specified amperage.

■

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

PX4800 & PX4800e - 15 - 11-06

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ENGLISH

TABLE 1

NOTE :

When the AC circuit breaker turns off during operation, the generator is over loaded or the appliance is defective. Stop the generator immediately, check the appliance and / or generator for overloading or detect and have repaired as necessary by Cummins Generator dealer or service shop.

■

To take power out from the TWIST LOCK RECEPTACLE, insert the plug into the receptacle, and turn it clockwise to the lock position.

■

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

WARNING

TWIST

up to 30A

up to 20A

NEMA

5-20R

NEMA

L14-20R

NEMA

L14-30R

NEMA

5-20P

NEMA

L14-20P

NEMA

L14-30P

GFCI (Ground Fault Circuit Interrupter) Receptacle, duplex

(REC1)

Locking Receptacle (REC2)

Locking Receptacle (REC4)

Style Ampere Receptacle AC plug Description

up to 30A

NEMA

L5-30R

NEMA

L5-30P

Locking Receptacle (REC3)

The duplex 120V receptacle is protected by a GFCI (Ground Fault Circuit Interrupter). GFCI shuts off the output current from the duplex 120V receptacle when a ground fault occurs in the generator or the appliance. Please note that other receptacles are not protected by GFCI.

［

CAUTION

］

PX4800 & PX4800e - 16 - 11-06

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(d) Turn the AC circuit breaker to the

position "ON".

(e) Turn on the switch of the appliance.

OFF

GFCI RECEPTACLE

After starting the engine, check the GFCI for proper functioning by the following test procedure.

■

Push blue TEST button, The red RESET button will pop out exposing the word TRIP. Power is now off at the outlets protected by the GFCI, indicating that the device is functioning properly.

■

If TRIP dose not appear when testing, do not use the generator. Call a qualified electrician.

■

To restore power, push RESET button.

If the RESET button pops out during operation, stop the generator immediately and call a qualified electrician for checking generator and the appliances.

WARNING

PX4800 & PX4800e - 17 - 11-06

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ENGLISH

Switch position Lower Voltage Receptacle Higher Voltage Receptacle

120V Activated full rated output N.A

120/240V Activated half of rated output Activated full rated output

FULL POWER SWITCH (Except PX2900)

Select the voltage using the FULL POWER SWITCH in accordance with the electrical appliance. Refer to TABLE 2.

120V

240V

Change the FULL POWER SWITCH after turning the AC circuit breaker to "OFF".

［

CAUTION

］

TABLE 2

PX4800 & PX4800e - 18 - 11-06

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IDLE CONTROL SWITCH (Except PX2900)

IDLE CONTROL

SWITCH

automatically reduces engine speed when load is OFF, and automatically increases engine speed to rated r.p.m. when load is ON. IDLE CONTROL

SWITCH

provides fuel economy and low noise operation at noload running.

(1) HOW TO USE IDLE CONTROL SWITCH

■

Start the engine with IDLE CONTROL SWITCH off.

NOTE :

Warm up the engine without a load for a few minutes.

■

Turn IDLE CONTROL SWITCH on.

(2) CHECKING THE OPERATION

When IDLE CONTROL

SWITCH does

not operate normally, please check following :

■

Overloaded ? Please make it sure that the generator is not overload.

NOTE :

Most induction loads such as electric motors require three to five times more wattage than their ratings during starting. This starting wattage should not exceed the rated output of the generator for proper operation of

IDLE CONTROL

SWITCH.

■

Turn

IDLE CONTROL SWITCH

off when the

IDLE CONTROL

SWITCH does not

work normally under the rated output.

NOTE :

The

IDLE CONTROL

SWITCH may not operate when the applied load is under 40W.

In such cases turn the

IDLE CONTROL SWITCH

off.

(3) STOPPING THE ENGINE

■

Turn off the switch of load.

■

Switch off generator's AC breaker.

■

Disconnect tool or appliance.

■

Turn the

IDLE CONTROL SWITCH

off.

■

Turn the STOP SWITCH to the position "O" (OFF).

NOTE :

Allow the engine about 3 minutes to cool down at no-load before stopping.

OFF

PX4800 & PX4800e - 19 - 11-06

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ENGLISH

(2) DC APPLICATION

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

CONNECTION OF CABLE :

■

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

■

Connect negative (black) terminal on generator to negative (

) terminal on

battery.

■

Both AC and DC output can be used at the same time if the total output is within rated output of the generator.

Red

Black

SAFETY PRECAUTIONS WHILE CHARGING

■

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

■

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

■

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

■

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

PX4800 & PX4800e - 20 - 11-06

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STOPPING THE GENERATOR

(a) Turn off the power switch of the

electric equipment and unplug the cord from receptacle of the generator.

(b) Turn the AC circuit breaker to the

"OFF" position.

cool down at no-load before stopping.

(d) Turn the Engine switch to the position

"OFF".

(e) Close the fuel cock.

OIL SENSOR

(a) The oil sensor detects the fall in oil

level in the crankcase and automati- cally stops the engine when the oil level falls below a predetermined level.

(b) When engine has stopped

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

starting procedures, check the oil level.

OPEN

Oil sensor

OFF

PX4800 & PX4800e - 21 - 11-06

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6. WATTAGE INFORMATION

ENGLISH

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

■

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

■

Loads such as fluorescent lamps require 1.2 to 2 times the indicated wattage during start-up.

■

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

■

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

■

Most electrical tools require 1.2 to 3 times their wattage for running under load during use. For example, a 5,000 watt generator can power a 1800 to 4000 watt electrical tool.

■

Loads such as submersible pumps and air compressors require a very large force to start. They need 3 to 5 times the normal running wattage in order to start. For example, a 5,000 watt generator would only be able to drive a 1,000 to 1,700 watt pump.

NOTE :

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

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

Applications

Applicable Wattage (W)

PX3600

2900

1500

PX2900

1100

60Hz

650

Incandescent lamp, Heater 2400

Fluorescent lamp, Electric tool 1200

Mercury lamp 900

Pump, Compressor 550 950

1500

2100

4100

PX4800

PX4800 & PX4800e - 22 - 11-06

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VOLTAGE DROP IN ELECTRIC EXTENSION CORDS

When a long electric extension cord is used to connect an appliance or tool to the generator, a certain amount of voltage drop or loss occurs in the extension cord which reduces the effective voltage available for the appliance or tool. The chart below has been prepared to illustrate the approximate voltage loss when an extension cord of 300 feet (approx. 100 meters) is used to connect an appliance or tool to the generator.

Nominal

cross

section

A.W.G.

Allowable

current

No.of strands

/ strands dia.

Resistance

Current Amp.

No./mm

Ω/100m

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

0.75 18 7 30/0.18 2.477 2.5V 8V

12.5V

─ ─ ─ ─

Voltage drop

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

─

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

3.5 12 to 10 23 45/0.32 0.517

─

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

5.5 10 to 8 35 70/0.32 0.332

─

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

PX4800 & PX4800e - 23 - 11-06

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7. SPARK ARRESTER

ENGLISH

In a dry or wooded area, it is recommendable to use the product with a spark arrester. Some areas require the use of a spark arrester. Please check your local laws and regulations before operating your

product

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

● Prevents the flow of exhaust gas

● Reduces engine output

● Increases fuel consumption

● Makes starting difficult

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

How to remove the spark arrester

1. Remove the flange bolts from the muffler cover and remove the muffler cover.

2. Remove the special screw from the spark arrester and remove the spark arrester from the muffler.

EXHAUST OUTLET

SPARK ARRESTER SCREEN

SCREW

MUFFLER COVER

Clean the spark arrester screen

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

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

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

SPARK ARESSTER SCREEN

PX4800 & PX4800e - 24 - 11-06

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8. MAINTENANCE SCHEDULE

DAILY INSPECTION

Before running the generator, check the following service items:

Excessive vibration,noise

Clean air cleaner element

Safe surroundings

Enough clean engine oil

Leakage of gasoline and engine oil

Loose or broken bolts and nuts

Enough gasoline

PERIODIC MAINTENANCE

Periodic maintenance is vital to safe and efficient operation of your generator. Check the table below for periodic maintenance intervals.

IT IS ALSO NECESSARY FOR THE USER OF THIS GENERATOR TO CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION- RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL SYSTEM EFFECTIVE.

The emission control system consists of the following parts :

The maintenance schedule indicated in the table is based on the normal generator operation. Should the generator be operated in extremely dusty condition or in heavier loading condition, the maintenance intervals must be shortened depending on the contamination of oil, clogging of filter elements, wear of parts, and so on.

(1) Carburetor and internal

parts

(2) Cold start enrichment

system, if applicable

(3) Intake manifold, if

applicable

(4) Air cleaner elements

(5) Spark plug

(6) Magneto or electronic

ignition system

(7) Spark advance/retard

system, if applicable

(8) Exhaust manifold, if

applicable

(9) Hoses, belts,

connectors, and assemblies

MAINTENANCE, REPLACEMENT, OR REPAIR OF THE EMISSION CONTROL DEVICES AND S YSTEMS MAY B E PERF ORMED B Y ANY NONRO A D ENG I NE RE PA IR ESTABLISHMENT OR INDIVIDUAL.

PX4800 & PX4800e - 25 - 11-06

Page 27

ENGLISH

*Note: 1. Initial oil change should be performed after first twenty (20) hours of operation.

Thereafter change oil every hundred (100) hours. Before changing oil, check for a suitable way to dispose of old oil. Do not pour it down into sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instructions on proper disposal.

*Note: 2. As to the procedures for these items, please refer to the SERVICE MANUAL or

consult your nearest service dealer.

Maintenance Items

Every

1000

hours

Every

500

hours

Every

200 hours

(Monthly)

Every 50 hours (Weekly)

Every

8 hours

(Daily)

Clean generator and check bolt and nuts

●

(Daily)

●(Daily)

● (Yearly)

●(Daily)

Check and refill engine oil

Change engine oil (*Note1)

Clean spark plug

Clean air cleaner

Replace air cleaner element

Clean fuel filter

Clean and replace carbon brushes

Remove carbon from cylinder head (*Note 2)

Check and adjust valve clearance (*Note 2)

Clean and adjust carburetor (*Note 2)

Replace fuel lines

Overhaul engine (*Note 2)

Check AC receptacles

Clean and adjust spark plug and electrodes

Replace spark plug

Check engine switch

Check DC termianl

Check rotor

Check stator

Replace engine mount

Periodic Maintenance Schedule table

●

(Refill daily up to upper level)

●(Initial

20 hours)

●(Every

100 hours)

Clean spark arrester

●

(Every 100 hours)

●

(Every 100 hours)

●

PX4800 & PX4800e - 26 - 11-06

Page 28

9. "HOW-TO" MAINTENANCE

ENGINE OIL CHANGE

■

Change engine oil every 100 hours. (For new engine, change oil after 20 hours.)

(a) Drain oil by removing the drain plug

and the oil filler cap while the engine is warm.

(b) Reinstall the drain plug and fill the

engine with oil until it reaches the upper level on the oil filler cap.

Oil drain plug

■

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

SERVICING THE AIR CLEANER

Element

Air cleaner cover

Base

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

(a) Unhook the cover and remove the

cleaner element.

(b) Urethane form : Wash the element

with fresh water. Squeeze out the water then dry the element. (Do not twist.)

PX4800 & PX4800e - 27 - 11-06

Page 29

ENGLISH

CLEANING AND ADJUSTING SPARK PLUG

(a)

If the plug is contaminated with carbon, remove it using a plug cleaner or wire brush.

(b) Adjust the electrode gap to 0.6 to 0.7

mm (0.024 to 0.028 in.).

Gap 0.6 to 0.7 mm (

0.024 to 0.028 in.

)

CLEANING FUEL STRAINER

Dirt and water in the fuel are removed by the fuel strainer.

(a) Remove the strainer cup and throw

away water and dirt.

(b) Clean the screen and strainer cup

with gasoline.

making sure to avoid fuel leak.

Spark plug :

BR-6HS (NGK) or RL86C (CHAMPION)

HIGH ALTITUDE ENGINE OPERATION

■ Please have an authorized Cummins Generator service dealer modify this engine

if it is to be run continuously above 5,000 feet (1,500 meters). Failure to do so, may result in poor engine performance, spark plug fouling, hard starting, and increased emissions.

■ Carburetor modification by an authorized Cummins Generator service dealer will

improve performance and allow that this engine meets EPA (Environmental Protection Agency) and California ARB (Air Resources Board) emission standards throughout its useful life.

■ An engine converted for high altitudes can not be run at 5,000 feet or lower.

In doing so, the engine will overheat and cause serious engine damage. Please have an authorized

Cummins Generator service dealer restore high altitude modified engines to the original factory specification before operating below 5,000 feet.

PX4800 & PX4800e - 28 - 11-06

Page 30

10. PREPARATION FOR STORAGE

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

■

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

■

Remove the carburetor float chamber and also drain the carburetor.

■

Change engine oil.

■

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

■

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

■

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

■

Store generator in a well ventilated, low humidity area.

Drain screw

PX4800 & PX4800e - 29 - 11-06

Page 31

11. TROUBLESHOOTING

ENGLISH

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

When Engine Fails to Start :

When No Electricity Is Generated at Receptacle :

Check if choke lever is in its proper position.

Check if fuel cock is open.

Check fuel level.

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

Check spark plug for loose spark plug cap.

Check spark plug for contamination.

Check if engine switch is in OFF.

Set the choke lever to "CLOSE"

position.

If closed, open fuel cock.

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

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

If loose, push spark plug cap back into place.

Remove spark plug and clean electrode.

Turn engine switch to ON.

Check to make sure AC circuit breaker

is in the "ON" position.

Check AC receptacle and DC terminals for loose connection.

Check to see if engine starting was

attempted with appliances already

connected to generator.

After making sure that the total wattage

of the electrical appliance is within

permissible limits and there are no

defects in the appliance, turn the AC

circuit breaker to the "ON" position.

If breakers continue to actuate, consult

your nearest servicing dealer.

Secure connection if necessary.

Turn off switch on the appliance, and

disconnect cable from receptacle.

Reconnect after generator has been

started properly.

PX4800 & PX4800e - 30 - 11-06

Page 32

12. WIRING DIAGRAM

Oil sensor

Ignition coil

Spark plug

Gry

Rec

Grn

ENGINE

GENERATOR

CONT.BOX

Blk

Grn

AC circuit breaker

Circuit breaker

Pilot lamp

Hour meter

Diode stack Assy

Rotor

Field

Winding

Winding 2

Winding 1

Winding

Condenser Winding

Engine switch

DC output terminal

Org

Brn/W

Earth (Ground) terminal

Condenser

Blk

Blu

Brn

Oil sensor

Ignition coil

Solenoid

Charge coil

Blu

LBlu

Rec1

Rec2

Rec3

Blk

Gry

Spark plug

Grn

AC circuit breaker

Pilot lamp

Hour meter

Circuit breaker

Full power switch

Idle control switch

ENGINE

GENERATOR

Rotor

CONT.BOX

Field

Winding

Winding 2

Winding 1

Winding

Condenser Winding

Grn

Idle

control

unit

Engine switch

DC output terminal

Org

Diode stack Assy

Brn/W

Earth (Ground) terminal

Condenser

Blk

Blu

Brn

PX2900 (60Hz-120)

PX3600 (60Hz-120/240V)

Blk : Black

Wiring color code

Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W : Green/White Org : Orange Gry : Gray R : Red W : White Y : Yellow

Grn/Y : Green/Yellow

W/Blk : White/Black

Pur : Purple

PX4800 & PX4800e - 31 - 11-06

Page 33

ENGLISH

ENGINE

Oil sensor

Ignition coil

Spark plug

Charge coil

Blu

LBlu

GENERATOR

Rotor

Blk

Blu

Brn

Org

Grn

Rec1

Rec2

Rec3

CONT.BOX

Blk

Grn

Field

Winding

Winding 2

Winding 1

Winding

AC circuit breaker

Pilot lamp

Hour meter

Circuit breaker

Circuit

breaker

Diode stack Assy

Full power switch

Idle

control

unit

Idle control switch

Solenoid

Condenser Winding

Engine switch

DC output terminal

Brn/W

Earth (Ground) terminal

CondenserCondenser

PX4800 (60Hz-120/240V)

Oil sensor

Ignition coil

Spark plug

Charge coil

Rec1

Rec2

Rec3

Fuse

Key switch

Org

Grn

-M

Gry

ENGINE

GENERATOR

Rotor

CONT.BOX

Field

Winding

AC circuit

breaker

Pilot lamp

Hour meter

Circuit breaker

Circuit

breaker

Diode stack Assy

Full power switch

Idle

control

unit

Idle control switch

Battery

Magnetiec switch

Electric

starter

Blu

LBlu

Blk

Solenoid

Winding 2

Winding 1

Winding

Condenser Winding

Grn

DC output terminal

Earth (Ground) terminal

Org

Brn/W

Condenser

Blk

Blu

Brn

PX4800[w / Starter motor] (60Hz-120/240V)

Blk : Black

Wiring color code

Blk/W : Black/White Blu : Blue LBlu : Light blue Brn : Brown Brn/W : Brown/White Grn : Green Grn/W : Green/White Org : Orange Gry : Gray R : Red W : White Y : Yellow

Grn/Y : Green/Yellow

W/Blk : White/Black

Pur : Purple

PX4800 & PX4800e - 32 - 11-06

Page 34