Cummins/Onan P3200i Generator Set

⚠ Any part with insulation resistance less than 1 MΩ has faulty insulation and may cause electric leakage and electric shock; replace the faulty part.

Tools: Megger tester, Cummins Onan generator tester

1. Use a Cummins Onan generator tester in megger mode or a megger tester (500V range).
2. Connect the tester to one receptacle output terminal and the ground terminal.
3. Measure the insulation resistance.
4. If below normal, disassemble and measure stator, rotor and control panel individually.
5. For stator, check resistance between red lead and core, blue lead and core, and white lead and core.
6. For control panel, measure resistances between live parts and grounded parts.

⚠ An inaccurate circuit tester may give erroneous readings.

Tools: Circuit tester

1. Disengage connectors on the wires from the stator.
2. Check the resistance between the wires using a circuit tester.
3. For inverter unit, check for color change or blister in the filling resin.
4. Check conductivity between the output wires and the 4P connector.

⚠ Failure to reattach foam rubber linings will result in poor performance and durability.

1. Memorize and tag the location of individual parts before disassembling.
2. Divide parts into groups and store them in boxes.
3. Replace bolts and nuts temporarily in their original positions.
4. Clean disassembled parts with neutral cleaning fluid before reassembly.
5. Remove the battery before disassembling the generator (electric start models).
6. Use the proper tool for each specific job.
7. Attach foam rubber linings inside covers on their original position; replace if deformed or damaged.
8. Bind wires and fuel pipes using wire bands as in original configuration.

⚠ Use caution not to break the gasket.

Tools: 10mm Box wrench

1. Remove the air cleaner cover and element from the air cleaner.
2. Loosen the two M6 nuts and one M6 bolt, and remove the air cleaner body.
3. Carefully remove the carburetor from the insulator without breaking the gasket.
4. Remove the sponge insulator.

⚠ Electric wires are still connected to the control panel; do not separate the control panel forcibly.

Tools: Screw driver, Nipper

1. Loosen the four screws and remove the upper front cover.
2. Loosen the two bolts and remove the lower front cover.
3. Loosen the five bolts and remove the cover bracket from the inverter unit.
4. Remove the fuel tank before separating the control panel.
5. Cut the wire bands binding wires behind the control panel.

Tools: 12mm Box wrench

1. Loosen the four M8 nuts that fasten the engine to the mount rubbers, and remove the engine.
2. Remove the mount rubbers from the frame as necessary.

Tools: Flywheel holder (33B9990101)

1. Wipe off oil from the tapered portion of the crankshaft and the hole of flywheel before assembly.
2. Install the flywheel onto the crankshaft and tighten the flywheel nut using the Flywheel Holder.

Tools: Flywheel holder (33B9990101), Socket wrench, Flywheel puller (available on market)

1. Using special tool Flywheel Holder to hold the flywheel, loosen the flywheel nut.
2. Remove the flywheel using an ordinary flywheel puller.

1. Turn the engine switch to STOP position to close the fuel cock.
2. Disconnect the two fuel pipes from the fuel strainer.
3. Remove the fuel strainer.
4. For electric start models: remove the battery cover and disconnect battery cables.
5. Remove the battery from frame.

Tools: 10mm Box wrench

1. Drain fuel from the tank before removing the tank.
2. Loosen the four bolts and remove the fuel tank from frame.
3. Take care not to misplace the four mounting rubbers for the tank.

⚠ Do not release pressure on the reel while winding the spiral spring; sudden rewinding may occur.

⚠ Wear protective goggles before assembly.

Tools: Protective goggles

1. Apply grease to the case; orient the inner end of the spring in the reel.
2. Hold the reel so the shaft and hook catch on the inner end of the spring, softly drop into the case from the top.
3. Move the reel gently counter-clockwise so the spring catches.
4. Install the ratchet and friction spring into the reel.
5. Install the friction plate tab into the hole of the ratchet and fasten with retaining ring C.
6. Hold the case and turn the reel five turns counter-clockwise.
7. Thread the rope end through the rope guide and reel hole, pull 20cm out and fix the rope end.
8. Hold the rope 50cm from the rope guide, gently release the reel to wind the rope until the knot reaches the rope guide.

⚠ Wear protective goggles before disassembly.

⚠ Spring pull is maximized while the rope is fully pulled out; do not release suddenly.

Tools: Long-nose pliers, Retaining-ring pliers, Protective goggles

1. Unhook the spring: pull out all rope, align rope guide and knot inside reel, hold reel with thumbs, pull knot from reel.
2. Slowly rewind the rope while controlling the reel with both thumbs.
3. Remove the retaining-ring C with ring pliers and remove friction plate and ratchet beginning at the top.
4. Move the reel left and right 1/4 turns several times, then slowly lift the reel from the case.
5. Repeat if the spiral spring sticks out.