Operator Manual Portable Generator Set EGMBD, EGMBD, EGMBD, EGMBE, EGMBE, EGMBE, EGMBE, English 12−2008 P5350ec P5350ce P5500ec P5450ec P5450ec P5550ec P6500ec 914−0103 (Issue 3)
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......................................................
Table of Contents 12-2008 4.2 General Inspections ............................................................................................................... 30 4.3 Changing Engine Oil .............................................................................................................. 30 4.4 Air Filter Maintenance ............................................................................................................ 31 4.5 Battery Maintenance ......................................
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.
1. Safety Precautions 12-2008 · 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.
12-2008 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.
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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.
2. Introduction 12-2008 FIGURE 2.
12-2008 2. Introduction No. Description No. Description 1 Fuel Tank Cap 6 Recoil Starter Grip 2 Fuel Gauge 7 Control Panel 3 Choke Lever 8 Muffler 4 Fuel Level 9 Spark Plug Boot 5 Air Cleaner NOTE: Carb models (P5350c and P5450ec) may include additional components not shown. FIGURE 3.
2. Introduction No. 12-2008 Description Description 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 4. 8 No.
12-2008 2.3 2. Introduction Wheel Kit The assembled wheel kit shown below is standard equipment on P5350, P5350c, P5450e, P5450ec, and P5550e models. FIGURE 5. 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.
2. Introduction 2.5 12-2008 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. CAUTION: Too little oil can cause severe engine damage. Make sure that the oil level is above the Add mark on the dipstick. 4.
12-2008 2. Introduction 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.
2. Introduction 2.7 12-2008 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.
3 Starting and Running the Generator Set 3.1 Control Panel The control panels are illustrated below. The control switches, meters, output receptacles, and circuit breaker reset buttons are grouped for convenient operation. No. Description No.
3. Starting and Running the Generator Set No. Description 12-2008 No. Description 1 On/Off Switch 5 AC Circuit Breaker Reset 2 Earth Ground Lug 6 One 120/240 VAC 30A Receptacle (L14-30R) 3 Two 120 VAC, 20A Receptacles (GFCI) 7 Two 120 VAC, 20A Receptacles 4 AC Circuit Breaker Reset FIGURE 8.
12-2008 No. 3. Starting and Running the Generator Set Description No. Description 1 On/Off Switch 5 AC Circuit Breaker Reset 2 Earth Ground Lug 6 One 120/240 VAC 30A Receptacle (L14-30R) 3 Two 120 VAC, 20A Receptacles (GFCI) 7 Two 120 VAC, 20A Receptacles 4 AC Circuit Breaker Reset FIGURE 9.
3. Starting and Running the Generator Set No. Description 12-2008 No. Description 1 Start/On/Off Switch 5 AC Circuit Breaker Reset 2 Earth Ground Lug 6 One 120/240 VAC 30A Receptacle (L14-30R) 3 Two 120 VAC, 20A Receptacles (GFCI) 7 Two 120 VAC, 20A Receptacles 4 AC Circuit Breaker Reset FIGURE 10.
12-2008 No. 3. Starting and Running the Generator Set Description No. Description 1 Start/On/Off Switch 5 AC Circuit Breaker Reset 2 Earth Ground Lug 6 One 120/240 VAC 30A Receptacle (L14-30R) 3 Two 120 VAC, 20A Receptacles (GFCI) 7 Two 120 VAC, 20A Receptacles 4 AC Circuit Breaker Reset FIGURE 11.
3. Starting and Running the Generator Set No. Description 12-2008 No. Description 1 Start/On/Off Switch 7 Two 120 VAC, 20A Receptacles (GFCI) 2 DC Breaker Reset Switch 8 One 120 VAC, 30A Receptacle (L5-30R) 3 AC Circuit Breaker Reset 9 120 VAC or 120/240 VAC Selector Switch 4 AC Voltmeter 10 One 120/240 VAC, 30A Receptacle (L14-30R) 5 AC Circuit Breaker Reset 11 Earth Ground Lug 6 12 Volt DC Terminals FIGURE 12.
12-2008 3.2 3. Starting and Running the Generator Set 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.
3. Starting and Running the Generator Set 12-2008 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 Periodic 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.
12-2008 3. Starting and Running the Generator Set 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. 3.3.
3. Starting and Running the Generator Set No. 12-2008 Description 1 Choke Lever 2 Open No. 3 FIGURE 14. FIGURE 15. 3.4 Description Close CHOKE ROD RECOIL START HANDLE 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.
12-2008 3. Starting and Running the Generator Set 3.5 Powering Tools and Appliances CAUTION: Continuous overloading can damage the generator set due to overheating. Make sure loading is within the generator set nameplate rating. 3.5.1 Voltage Selector Switch An AC voltage selector switch is available on P5550e, P5500, and P6500 portable generator sets. To Power 120/240 Volt AC Circuits: Push the voltage selector switch on the control panel towards the 120/240 Volt output receptacle.
3.
12-2008 3.6 3. Starting and Running the Generator Set 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. Acring at battery terminals can ignite batterey gases.
3. Starting and Running the Generator Set 3.10 12-2008 Electrical Interference with Communications or Appliances If the generator set causes electrical interference with communications devices, move the generator set and device farther apart or shut down the generator set while the device is operating. 3.11 Exercising the Generator Set Exercise the generator set at least two hours every month if use is infrequent. Run it at approximately 50 percent capacity.
12-2008 3. Starting and Running the Generator Set No. 1 Description Fuel Drain Bolt FIGURE 16. CARBURETOR DRAIN 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 the figure above. 3. Remove the spark plug. Squirt one tablespoon (about 1 ounce / 30 cm3) of clean engine oil into the spark plug hole.
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4 Maintenance 4.1 Maintenance Schedule Periodic maintenance is essential for top performance. Use the Table below as a guide. Under hot or dusty operating conditions some maintenance operations should be performed more frequently, as indicated by the footnotes in the table. Keep a log of maintenance performed and the hours run. Recording maintenance will help you keep it regular and provide a basis for supporting warranty claims. WARNING: Contact with a hot generator set can cause severe burns.
4. Maintenance 4.2 12-2008 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.
12-2008 4. Maintenance No. Description No. Description 1 Oil Filler Cap 4 Upper Level 2 Oil Drain Bolt 5 Lower Level 3 Oil Fill Tube FIGURE 17. 4.4 OIL CHECK, FILL, AND DRAIN Air Filter Maintenance Refer to the "Maintenance Schedule" section for scheduled air filter maintenance. Clean more often in dusty environments. 1. Remove the filter cover by unsnapping the two spring clips. 2. Remove the two foam filter elements and thoroughly wash them with soap and water. Let them dry thoroughly.
4. Maintenance No. 12-2008 Description 1 Clip 2 Air Cleaner Cover No. 3 FIGURE 18. 4.5 Description Air Cleaner Element AIR CLEANER Battery Maintenance Refer to the Periodic Maintenance Schedule table for scheduled battery maintenance. Carefully follow the battery manufacturer's instrucitons. 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.
12-2008 4. Maintenance FIGURE 19. 4.6 BATTERY MOUNTING Fuel Sediment Cup Cleaning Refer to the "Maintenance Schedule" section for scheduled cleaning. Have the filter replaced if the fuel has been contaminated or the engine seems to have lost power. Cleaning and replacement must only be performed by an authorized Cummins Onan dealer. 4.7 Spark Plug Maintenance Refer to the "Maintenance Schedule" section for scheduled spark plug maintenance.
4. Maintenance 12-2008 WARNING: Contact with hot generator parts can cause severe burns. Always allow the generator set to cool before performing any maintenance or service. 1. Turn off the generator set and allow it to cool down. 2. Remove the spark plug cap. 3. Clean any dirt from around the spark plug base. 4. Use the wrench supplied in the tool kit to remove the spark plug. 5. Visually inspect the spark plug. Discard it if the insulator is cracked or chipped.
12-2008 4. Maintenance CAUTION: Cleaning the generator set with a pressure washer can cause damage to the generator set by shorting the generator and other electrical components. Do not use a pressure washer to clean the generator set. Wear safety glasses if it is necessary to use compressed air to clean the engine cooling fins. Do not use a pressure washer to clean the generator set. Water can enter the generator and other electrical components causing shorts that can disable the generator set.
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5 Troubleshooting The following troubleshooting guide can be used for basic problem diagnosis. If these recommendations do not resolve the problem, contact an authorized Cummins Onan service center. WARNING: Many troubleshooting procedures or replacement of parts present hazards that can result in equipment damage and severe personal injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity, and machinery hazards should perform service procedures.
5. Troubleshooting 12-2008 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. WARNING: Contact with a hot generator set can cause severe burns.
12-2008 5. Troubleshooting 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. WARNING: Contact with a hot generator set can cause severe burns.
5. Troubleshooting 12-2008 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. WARNING: Contact with a hot generator set can cause severe burns.
6 Specifications TABLE 4. SPECIFICATIONS FOR P5350 AND P5350C (EGMBD) P5550E, P5450E, AND P5450EC (EGMBE) P5350 and P5350c (EGMBD) P5550e (EGMBE) P5450e and P5450ec (EGMBE) 60 Hz 60 Hz 60 Hz 120 / 240 Volts 120 / 240 Volts 120 / 240 Volts Rated Power 5000 Watts 5000 Watts 5000 Watts Max. Output 5300 Watts 5500 Watts 5400 Watts 41.7 / 20.9 Amps 41.7 / 20.9 Amps 41.7 / 20.9 Amps 12 VDC / 8.3 Amps 12 VDC / 8.3 Amps 12 VDC / 8.3 Amps 3600 3600 3600 Gasoline Gasoline Gasoline 1.
6. Specifications TABLE 5. 12-2008 SPECIFICATIONS FOR P5500 (EGMBD) AND P6500 (EGMBE) GENERATOR P5500 (EGMBD) P6500 (EGMBE) 60 Hz 60 Hz 120 / 240 Volts 120 / 240 Volts Rated Power 4000 Watts 5000 Watts Rated Current 33.3 / 16.7 Amps 41.6 / 20.8 Amps 12 VDC / 8.3 Amps 12 VDC / 8.3 Amps AC OUTPUT: Frequency (Hertz) Voltage DC OUTPUT: ENGINE Engine Type Single Cylinder, Forced Air Cooling, 4-Stroke Engine Speed (RPM) 3600 3600 Gasoline Gasoline 1.16 US qt (1.1 L) 1.16 US qt (1.
7 Important Information for California Users NOTE: This section applies to P5350C and P5450ec models. It also applies to P5500 and P6500 models built before 2008. These generator sets meet the requirements of California’s Exhaust Emissions Standards for Utility and Lawn and Garden Equipment Engines, which correspond to the engine class, the year manufactured, and the date of the original sale, if equipped with an emissions label so stating.
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Cummins Power Generation 1400 73rd Ave. NE Minneapolis, MN 55432 USA Phone 1 763 574 5000 Toll-free 1 800 888 6626 Fax 1 763 574 5298 Email www.cumminsonan.com/contact www.cumminsonan.com CumminsR, OnanR, the “C” logo, and “Performance you rely on.” are trademarks of Cummins Inc. E2008 Cummins Power Generation, Inc. All rights reserved.
