Cummins/Onan P216 Generator Set

⚠ If it is necessary to make adjustments while the engine is running, use extreme caution when close to hot exhausts, moving parts, etc.

1. Start the engine and allow it to warm up thoroughly (at least 10 minutes).
2. Move the engine speed control to the slow position.
3. Bend or turn the low speed stop on the governor so the throttle stop screw on the carburetor controls engine speed.
4. Adjust the throttle stop screw for 1000 rpm idle.
5. Adjust the governor low speed stop for 1100 rpm idle.
6. Move the engine speed control to the fast position.
7. Bend the high speed stop on the governor so the engine runs at the equipment manufacturer's recommended speed.

1. Start engine and allow to warm up at least 10 minutes
2. Move engine speed control to slow position; adjust throttle stop screw for 1000 rpm idle
3. Adjust governor low speed stop for 1100 rpm idle
4. Move engine speed control to fast position; bend high speed stop on governor to set equipment manufacturer's recommended speed

Tools: 1/8 inch drill bit, wrench

1. Shut off engine, remove air cleaner outer cover and filter element.
2. Loosen choke rod swivel clamp screw.
3. Lock throttle control lever with pin (1/8 inch drill bit) so pin acts as stop for choke lever.
4. Push choke rod towards carburetor to fully open choke.
5. Rotate choke lever towards carburetor until it bears against pin stop, tighten swivel clamp screw.
6. Remove lock pin and check choke linkage operation. Replace damaged components.
7. Reassemble air cleaner.
8. Adjust throttle and choke control cables.

Tools: 1/8 inch drill bit, wrench

1. For single-cable: shut off engine, loosen throttle cable clamp.
2. Lock throttle lever with pin (1/8 inch drill bit).
3. Push speed control lever to high speed position.
4. Hook cable wire into throttle lever, pull out slack, tighten clamp. Remove lock pin.
5. For two-cable: repeat steps 1-3, then push choke knob to full-open.
6. Hook choke cable wire into choke lever, push choke rod towards carburetor, pull out slack, tighten clamp.

Tools: torque wrench, shims

1. Tighten the oil base to the torque recommended in Section 4 Assembly.
2. Check the crankshaft endplay and compare it with Section 3 Dimensions and Clearances.
3. If endplay exceeds the specified limits, remove the oil base and add shim(s) between the thrust washer and the oil base.
4. Install the oil base, making sure the thrust washer and shim notches line up with the lock pins.
5. Torque the oil base and check the endplay again.

⚠ Adjusting the engine speed to a value above that specified by the equipment manufacturer could cause the equipment to operate at speeds in violation of Federal and State Standards for Safety for the equipment.

⚠ Moving parts can cause severe personal injury or death. Take care when measuring engine speed with a tachometer and follow the meter instructions. You must be a qualified mechanic.

Tools: tachometer

1. Normally no need to adjust engine speed. Instructions are for equipment manufacturer. Attempt only by qualified mechanic using accurate tachometer.
2. Set low-idle and high-idle speeds to values specified in equipment Operator's Manual. If absent, adjust low-idle to 1,100 RPM and high-idle to 3,400 RPM.
3. Start engine, observing all equipment manufacturer's instructions and precautions.
4. If throttle cable already connected, loosen clamp at engine and back out low-idle speed stop screw so speed stop screw on carburetor touches its stop. Adjust engine speed to 1,000 RPM with carburetor
5. Turn low-idle speed stop screw to obtain specified low-idle speed.
6. Move engine throttle link up against its stop tang and hold it there while bending tang as necessary to obtain specified high-idle speed.
7. Hook engine throttle link with throttle cable, pull slack out of throttle cable and tighten clamp. Check for full, smooth movement of engine throttle link between its two stop positions when equipment

⚠ Engine speed adjustment must be attempted only by a qualified mechanic using an accurate tachometer.

⚠ Adjusting the engine speed above that specified by the equipment manufacturer could cause the equipment to operate at speeds in violation of Federal and State Standards for Safety.

⚠ Moving parts can cause severe personal injury or death. Take care when measuring engine speed with a tachometer.

Tools: Accurate tachometer

1. Start the engine, observing all equipment manufacturer's instructions and precautions.
2. If the throttle cable is connected, loosen the clamp at the engine and back out the low-idle speed stop screw so the carburetor speed stop screw touches its stop.
3. Adjust engine speed to 1000 RPM with the carburetor speed stop screw.
4. Turn the low-idle speed stop screw to obtain the specified low-idle speed.
5. Move the engine throttle link up against its stop tang and hold it there while bending the tang as necessary to obtain the specified high-idle speed.
6. Hook the engine throttle link with the throttle cable, pull out slack and tighten the clamp.
7. Check for full, smooth movement of the engine throttle link between its two stop positions through the full range of the equipment throttle lever.

⚠ Adjusting engine speed above equipment manufacturer spec could cause violation of safety standards.

⚠ Moving parts can cause severe personal injury or death.

Tools: tachometer, 1/8 inch drill bit, wrench

1. Remove outer cover of air cleaner and set up tachometer.
2. Start engine.
3. Lock throttle control lever with pin (1/8 inch drill bit) in control plate.
4. Loosen choke rod swivel clamp screw and push choke rod towards carburetor to fully open choke.
5. Adjust high-idle speed by rotating engine control plate. Loosen pivot bolt 1/8 turn and set bolt 1/4 turn. Retighten.
6. Adjust low-idle speed by turning idle speed screw. Remove lock pin and move throttle to lowest position.
7. Shut off engine and readjust choke.

⚠ Adjusting engine speed above that specified by the equipment manufacturer could violate Federal and State Standards for Safety

⚠ Only a qualified mechanic should adjust engine speed

Tools: Accurate tachometer

1. Start the engine, observing all equipment manufacturer instructions and precautions.
2. Loosen throttle cable clamp and back out low-idle speed stop screw so carburetor speed stop screw touches its stop.
3. Adjust engine speed to 1000 RPM with the carburetor speed stop screw.
4. Turn the low-idle speed stop screw to obtain the specified low-idle speed.
5. Move the engine throttle link against its stop tang and bend the tang for specified high-idle speed.
6. Hook throttle link with the cable, remove slack and tighten the clamp.
7. Check for full, smooth movement of the throttle link between its two stop positions.

⚠ Accidental starting can cause severe injury or death. Always disconnect spark plug and battery before resetting engine control cables.

1. Stop engine and disconnect spark plug and battery (negative cable).
2. Push choke knob in to full open-choke position and throttle lever to lowest speed position.
3. Loosen cable clamp at engine bracket if necessary and hook cable wires into hook holes in choke and throttle control arms.
4. Rotate choke and throttle control arms clockwise, hold against stops, pull slack out of cables and tighten cable clamp.
5. Check for smooth movement and full travel of choke knob and throttle lever. Remove air cleaner element to see choke plate opens and closes fully. Check throttle control arm touches stop plate and thro
6. Reassemble air cleaner and reconnect spark plug and battery.

⚠ Accidental starting of the engine can result in severe personal injury or death. Always disconnect the spark plug and battery (negative [-] cable) before resetting the engine control cables.

1. Stop the engine and disconnect the spark plugs and, if so equipped, the battery negative (-) cable.
2. Push the equipment choke knob to the full-open choke position.
3. Connect the choke cable to the choke lever (hook into the lever or clamp with the screw in a swivel on the lever); pull out cable slack and clamp.
4. Check for smooth movement and full travel of the equipment choke knob.
5. Remove the air cleaner element to see that the choke plate opens and closes fully.
6. Reassemble the air cleaner and reconnect the spark plug and battery.

Tools: feeler gauge, 7/16-inch open end wrench, 9/16 inch (14 mm) open end wrench, torque wrench

1. Remove the ignition key to prevent accidental starting.
2. Remove all parts necessary to gain access to the valve tappets.
3. Remove the spark plugs to ease turning the engine over by hand.
4. Rotate the crankshaft clockwise until the right intake valve opens and closes.
5. Continue turning until the flywheel timing mark lines up with the governor shaft on the gear cover.
6. Verify the left intake and exhaust valves are closed and there is no pressure on the valve lifters.
7. Check that the correct feeler gauge passes freely between valve cap and tappet; a 0.002 inch thicker gauge should not.
8. Turn the adjusting screw with a 7/16-inch open end wrench to obtain correct clearance; hold the tappet with a 9/16 inch (14 mm) wrench.
9. For the left cylinder, turn the engine one complete revolution, line up the timing marks, and repeat.
10. Replace all removed parts, tighten all screws securely, and torque valve cover bolts to specification.