Onan EGMBT P4500, EGMBU P5000e Service Manual Cummins Onan Generator Service Repair Book 914-0508
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Service Manual
Portable Generator Set
EGMBT, P24500 (Spec A)
EGMBU, P5000e (Spec A)
English 10−2009 914−0508 (Issue 5)
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.................................................................................................................................. 5
2.4 Fuel Requirements................................................................................................................... 6
2.5 Generator Set Assembly Instructions ...................................................................................... 6
2.6 Wheel Kit Assembly Instructions ............................................................................................. 8
2.7 Starting Battery ........................................................................................................................ 9
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 Pre-Start Checks.................................................................................................................... 13
4.3 Starting the Generator Set ..................................................................................................... 15
4.4 Stopping the Generator Set ................................................................................................... 17
4.5 Powering Tools and Appliances ............................................................................................ 18
4.6 Charging Batteries ................................................................................................................. 20
4.7 Circuit Breakers ..................................................................................................................... 20
4.8 Grounding .............................................................................................................................. 20
4.9 Low Oil Shutdown .................................................................................................................. 21
4.10 Electrical Interference with Communications or Appliances ................................................ 21
4.11 Exercising the Generator Set ............................................................................................... 21
4.12 Engine Break-In ................................................................................................................... 21
4.13 Out-of-Service Protection..................................................................................................... 22
914-0508 (Issue 5) i
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 ........................................................................................................... 35
7.3 Torque Specifications ............................................................................................................ 35
7.4 Standard Torque Specifications ............................................................................................. 36
8. MAINTENANCE ............................................................................................................................ 37
8.1 Maintenance Schedule .......................................................................................................... 37
8.2 General Inspections ............................................................................................................... 38
8.3 Engine Oil .............................................................................................................................. 38
8.4 Air Filter Maintenance ............................................................................................................ 40
8.5 Fuel Sediment Cup Cleaning ................................................................................................. 41
8.6 Cleaning the Spark Arrester .................................................................................................. 42
8.7 Valve Clearance..................................................................................................................... 43
8.8 Governor Adjustments ........................................................................................................... 44
9. SERVICING THE GENERATOR SET .......................................................................................... 47
9.1 Preparing for Service ............................................................................................................. 47
10. CONTROL PANEL....................................................................................................................... 51
10.1 Control Panel Components .................................................................................................. 51
10.2 Control Panel Service .......................................................................................................... 52
11. GENERATOR SERVICE ............................................................................................................. 61
11.1 Charging Coil ....................................................................................................................... 61
11.2 Generator Disassembly ....................................................................................................... 63
11.3 Generator Reassembly ........................................................................................................ 65
11.4 Brush Block and Slip Rings ................................................................................................ 66
11.5 Generator Component Testing ............................................................................................ 66
12. ENGINE ....................................................................................................................................... 71
12.1 Cylinder Head / Valves ........................................................................................................ 71
12.2 Camshaft / Crankshaft ......................................................................................................... 77
12.3 Piston ................................................................................................................................... 82
12.4 Oil Level Switch ................................................................................................................... 87
13. FUEL, START, AND IGNITION SYSTEMS ................................................................................. 89
13.1 Fuel System ......................................................................................................................... 89
ii 914-0508 (Issue 5)
10-2009 Table of Contents
13.2 Choke Assembly .................................................................................................................. 92
13.3 Governor Assembly ............................................................................................................. 93
13.4 Carburetor ............................................................................................................................ 95
13.5 Fuel Cut-Off Solenoid .......................................................................................................... 97
13.6 Starting System.................................................................................................................... 97
13.7 Ignition System .................................................................................................................. 105
14. INTAKE / EXHAUST SYSTEM .................................................................................................. 115
14.1 Muffler ................................................................................................................................ 116
14.2 Air Cleaner ......................................................................................................................... 117
15. TROUBLESHOOTING ............................................................................................................... 121
15.1 Engine Won't Crank (Manual Start) ................................................................................... 121
15.2 Engine Won't Crank (Electric Start) ................................................................................... 121
15.3 Engine Cranks But Won't Start .......................................................................................... 122
15.4 Engine Starts But Stops Suddenly..................................................................................... 122
15.5 Starting Battery Runs Down .............................................................................................. 123
15.6 Unstable Speed ................................................................................................................. 123
15.7 Abnormal Exhaust Color .................................................................................................... 124
15.8 Low Engine Speed ............................................................................................................. 125
15.9 Low Power ......................................................................................................................... 125
15.10 No DC Output Voltage ..................................................................................................... 126
15.11 No AC Output Voltage ..................................................................................................... 127
16. SERVICE CHECKLIST .............................................................................................................. 129
16.1 Mounting ............................................................................................................................ 130
16.2 Lubrication ......................................................................................................................... 130
16.3 Wiring ................................................................................................................................. 130
16.4 Initial Start Adjustments ..................................................................................................... 130
16.5 Exhaust System ................................................................................................................. 131
16.6 Fuel System ....................................................................................................................... 131
16.7 Output Check ..................................................................................................................... 131
16.8 Control ............................................................................................................................... 131
16.9 Mechanical ......................................................................................................................... 131
17. WIRING DIAGRAMS ................................................................................................................. 133
17.1 Wiring Diagram of EGMBT / P4500 ................................................................................... 133
17.2 Wiring Diagram of EGMBU / P5000e ................................................................................ 134
18. MAINTENANCE RECORD ........................................................................................................ 135
914-0508 (Issue 5) iii
Table of Contents 10-2009
19. GLOBAL ADDRESSES ............................................................................................................. 137
iv 914-0508 (Issue 5)
1 Safety Precautions
Thoroughly read the Operator Manual before operating the generator set. Safe operation
and top performance can only be obtained when equipment is operated and maintained
properly.
The following symbols, found throughout this manual, alert you to potentially dangerous
conditions to operators, service personnel, and the equipment.
DANGER: This symbol alerts you to an immediate hazard that will result in
severe personal injury or death.
WARNING: This symbol alerts you to a hazard or unsafe practice that can result in
severe personal injury or death.
CAUTION: This symbol alerts you to a hazard or unsafe practice that can result in personal
injury or damage to equipment or property.
1.1 Exhaust Gas Is Deadly
· Operate the generator set outdoors only. Stay away from the exhaust outlet.
· Make sure generator set exhaust will not enter windows, doors, vents, or air intakes of
adjacent buildings, vehicles, or boats.
· NEVER USE THE GENERATOR SET INSIDE a home, garage, crawl space, barn, shed,
cabin, boat, boat house, RV, or tent; or in a confined outdoor space such as an alley, ditch,
parking garage, or courtyard; or in any other space where exhaust can accumulate. Note
that HAZARDOUS CARBON MONOXIDE LEVELS FROM ENGINE EXHAUST CAN
ACCUMULATE INDOORS, EVEN WHEN ALL WINDOWS AND DOORS ARE OPEN AND
FANS ARE RUNNING.
· Even when you use a generator set correctly, CO may leak into the home. ALWAYS use a
battery-powered or battery-backup CO alarm in the home.
· If you feel sick, dizzy, or weak after the generator set has been running, move to fresh air
RIGHT AWAY. See a doctor. You could have carbon monoxide poisoning.
1.2 Gasoline is Flammable / Explosive
· Refuel the generator set outdoors only.
914-0508 (Issue 5) 1
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.
2 914-0508 (Issue 5)
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.
914-0508 (Issue 5) 3
1. Safety Precautions 10-2009
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4 914-0508 (Issue 5)
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$36.99
The Onan Cummins EGMBT P4500 and EGMBU P5000e Generator Service Repair Manual is a comprehensive workshop manual designed to provide detailed servicing instructions for professional mechanics and DIY enthusiasts. This manual includes complete information on repair, servicing, preventative maintenance, and troubleshooting procedures for your Onan Cummins Generator.
Featuring step-by-step instructions, detailed illustrations, and photos, this manual is an indispensable source of maintenance and repair information. It covers major engine service, engine sensors, governor actuator, exhaust manifold, fuel system, starter, battery charging alternator, generator testing, disassembly, reassembly, reconnecting the generator, line circuit breakers, safety precautions, control panel operation, engine oil recommendations, engine coolant, periodic maintenance, generator set control, specifications, and wiring diagram.
The manual is available in a printable format and is instantly accessible, allowing for easy navigation to identify the exact service repair procedures in the quickest time possible. It will help you better understand, care for, and service your Onan Cummins Generator, ultimately lowering the repair and maintenance costs.
This service repair manual covers the following Onan Cummins Generator models:
- EGMBT P4500 (SPEC A)
- EGMBU P5000e (SPEC A)
After purchasing the manual, you can instantly access and view it. It is fully printable, allowing you to print pages whenever needed.
