Onan EGH User manual

EGH, EGS
Printed in U.S.A.
981 -01 30
2-94

Safety Precautions
Before operating the generator set, read the Operatois
Manualandbecomefamiliarwith itandyour equipment. Safe
andefficient operationcanbeachievedonly iftheequip-
ment
is properlyoperatedandmaintained. Manyaccidents
arecausedbyfailure tofollowfundamentalrulesandprecau-
tions.
Thefollowingsymbols,foundthroughoutthismanual,alertyou
to potentiallydangerousconditions to theoperator,serviceper-
sonnel, ortheequipment.
This symbol warns of immediate haz-
ards which will result in severe personal injury or
death.
Thissymbolrefers to
a hazardor unsafe
practice which can result in severe personal injury
or death..
'-1 Thissymbolreferstoahazard or unsafe
practice whichcanresultinpersonal injuryorprod-
uct or property damage.
Fuels,electricalequipment,batteries,exhaustgasesandmov-
ingpartspresentpotentialhazardsthat couldresultinsevere
personalinjury. Take careinfollowingthese recommended
procedures.
FUELAND FUMES ARE FLAMMABLE. Fire,explosion, and
severe personalinjury can resultfrom improperpractices.
DO NOT fillfueltankswiththeengine running. Fuelcon-
tactwithhotengine
or exhaust is a potentialfirehazard.
DO NOTSMOKE OR ALLOWANOPENFLAMEnearthe
generatorset or fueltank.
DO NOTstoreortransportthegeneratorset without first
removingthefuelfromthefueltank.
DO NOTSMOKEwhileservicingbatteries. Leadacidbat-
teriesemitahighlyexplosivehydrogengasthatcanbe
ig-
nitedby electrical arcingor bysmoking.
EXHAUSTGASES ARE DEADLY
Engineexhaust containsCARBON MONOXIDE, a dan-
gerousgasthatispotentiallylethal. Avoidcarbonmonox-
ide inhalation by operating the generator set outdoors
where exhaust gasescan bedischargeddirectly intothe
openair.
Do notoperatethegeneratorset inanytype of enclosure
thatcouldallowexhaust gasestoaccumulate. Directex-
haustgasawayfromareaswherepeoplearegatheredand
awayfrom buildingsor enclosures.
MOVING PARTSCAN CAUSE SEVERE PERSONAL
INJURY OR DEATH
Beforeperforminganymaintenanceonthegeneratorset,
disconnectthe spark plugwire (and the starting battery
negative
[-I cableonelectricstartsets)topreventacciden-
talstarting.
Keephandsaway from movingparts.
Donotwear looseclothingorjewelrywhileservicingany
partof thegeneratorset. Looseclothingandjewelrycan
become caught in moving parts. Jewelry can short out
electricalcontactsandcauseshock or burning.
Makesurethatfastenersonthegeneratorsetaresecure.
Tightensupportsandclamps,keepguardsinpositionover
fans, drivebelts, etc.
Ifadjustmentsmustbemadewhilethegeneratorsetisrun-
ning,useextremecautionaround
hot manifoldsandmov-
ingparts, etc.
ELECTRICAL SHOCK CAN CAUSESEVERE
PERSONAL INJURY OR DEATH
Disconnect starting battery before removing protective
shieldsor touchingelectrical equipment. Use rubberin-
sulativematsplacedondrywoodplatformsoverfloorsthat
aremetalor concretewhen aroundelectricalequipment.
Donotweardampclothing(particularlywetshoes)orallow
skin surface
to be damp when handlingelectricalequip-
ment.
Use extreme caution when working on electricalcompo-
nents. Highvoltagescancauseinjuryordeath. DONOT
tamperwithinterlocks.
Followallapplicablestateandlocalelectricalcodes. Have
allelectricalinstallationsperformedbyaqualifiedlicensed
electrician.Tagopenswitches
to avoidaccidentalclosure.
DO NOT CONNECT GENERATOR
SET DIRECTLY TO
ANY BUILDINGELECTRICALSYSTEM. Hazardousvolt-
agescan flowfromthe generatorset into the
utili linc
Thiscreatesapotentialforelectrocutionorpropertydam
age. Connectonlythroughanapproveddeviceandafte
buildingmainswitchisopen. Consultanelectricianinre-
gardto emergencypoweruse.
GENERALSAFETY PRECAUTIONS
Have afire extinguisher nearby. Maintainextinguisher
properlyandbecomefamiliarwith itsuse. Extinguishers
ratedABCbytheNFPAareappropriateforallapplications.
Consultthelocalfiredepartmentforthecorrecttype
of ex-
tinguisherfor various applications.
Benzeneand lead, found in some gasoline, have been
identifiedbysomestateand federalagencies ascausing
cancer or reproductivetoxicity. Whenchecking, draining
or adding gasoline, take care not
to ingest, breathethe
fumes, or contact gasoline.
Usedengineoilshavebeenidentifiedbysomestateorfed-
era1agenciesas causing cancer or reproductivetoxicity.
Whenchecking
or changingengineoil, takecarenottoin-
gest, breathethefumes, or contactusedoil.
Removeallunnecessarygreaseandoilfromtheunit. Ac-
cumulatedgreaseandoilcancauseoverheatinganden-
ginedamage, andpresentapotentialfirehazard.
DO NOTstoreanythingon the generator set such asoil
cans, oilyrags, chains, wooden
blocks, etc. A firecould
result
or operationcouldbeadverselyaffected. Keepthe
generatorset clean anddry atalltimes.
Donotworkonthisequipmentwhenmentallyorphysicall)
fatigued, or after consuming any alcohol or drug that
makesthe operation of equipmentunsafe.
'
KP-7

Table of Contents
SECTION TITLE PAGE
1 INTRODUCTION ...................................................... 1-1
About this Manual ................................................. 1-1
How to ObtainService .............................................. 1-1
2 SPECIFICATIONS .................................................... 2-1
Pre-StartChecks .................................................. 3-1
RecommendedFuels ............................................... 3-1
Grounding Requirements ........................................... 3-1
ControlPanel ...................................................... 3-3
Adding Loads ..................................................... 3-6
CircuitBreakers ................................................... 3-7
OilWatchIndicator ................................................. 3-7
Stopping .......................................................... 3-7
High/Low OperatingTemperatures .................................. 3-7
ExtremelyDustyor Dirty Conditions .................................... 3-8
GeneratorSet Exercise ............................................. 3-8
TroubleshootingGuide ............................................. 3-8
4 MAINTENANCE ..................................................... 4-1
PeriodicMaintenanceSchedule ..................................... 4-1
GeneralInspection ................................................. 4-2
LubricationSystem ................................................. 4-2
Air Filter .......................................................... 4-3
Spark Plug ........................................................ 4-4
MufflerService .................................................... 4-4
FuelFilter ......................................................... 4-4
BatteryCare ....................................................... 4-5
Cleaningthe GeneratorSet ......................................... 4-5
EngineSpeed ..................................................... 4-6
Out-of-Service Protection .......................................... 4-7
3 OPERATION ........................................................ 3-1
General ........................................................... 3-1
Starting ........................................................... 3-3
General ........................................................... 4-1
i

Section 1 Introduction
ABOUT THIS MANUAL
This manual provides information for operating and
maintainingtheOnanStandardandProSeriesportable
generatorsets. Studythismanualcarefullyandcomply
withallwarningsandcautions.Usingthegeneratorset
properlyandfollowingaregularmaintenanceschedule
will result in longer generator set life, better perfor-
mance, and safer operation.
HOW TO OBTAIN SERVICE
When the generator set requires service, contact an
OnanAuthorizedServiceCenterforassistance.Factory
trained Onan parts and service representatives are
readyto handleyour serviceneeds.
A copy ofthewarrantyform isintheliteraturepackage
includedwith each
unit. A servicemanual is available
onspecialorderthroughanOnandealerordistributor.
When contactinganauthorizedservicecenterfor parts
or service, supply the complete model number and
serialnumber listed
on the nameplate(Figure 1-1).
~ ~~ ~ ~
ELECTRIC. GENERATOR
IMPORTANT
WHEN WRITING ABOUT SERSICE
OR PARTS
GIVE MODEL AND SERIAL NUMBER
MODEL NUMBER
1-1
SER. NO.
I I
WATTS : MAXIMUM/RATED 71
AMPS. /RATED 1.1
VOLTS : -1
CYCLE 1-1 P.F.1-1
PHASE 1-1 RPM -1
FIGURE 1-1. NAMEPLATE
laWAR"G(
INCORRECT SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN
SEVERE PERSONALINJURY, DEATH, AND/OR EQUIPMENT DAMAGE.
SERVICEPERSONNEL
MUST BE QUALIFIEDTOPERFORMELECTRICAL
AND/OR MECHANICALSERVICE.
1-1

. STANDARD
1.4EGSAA
FUEL FILL
RECOIL STARTER
111-1802
STANDARD 1.7 EGIUW2.5 EGHAA
RECEPTACLES
OIL FILL (OTHER SIDE)
CIRCUIT BREAKERS
AIR FILTER
MUFFLER
r
FIGURE 1-2. PORTABLEGENERATOR SETS
1 -2

PRO 2.5 EGHAA
COMROI
RECOIL STI
-PANEL
\
/
WER
OILFILL
PRO 4.0 EGHAB
FUEL FILL
CONTROLPANEL
1
RECOIL STA#IER
FUEL FILL
M-1833
OIL FILL
FIGURE 1-3. PORTABLE GENERATOR SETS
1 -3

PRO 5.0 EGHEB
RECOIL
I
OIL FILL
PRO 6.0 EGHEB
CONTROL PANEL
\
RECOIL STARTER
ELECTRIC STAR
OIL FILL
FIGURE 1-4. PORTABLE GENERATOR SEfS
NEL ALL
FUEL FILL
1 -4

.
~ ~~
MODEL
GENERATOR DETAILS
AC OUTPUT - 60 HERTZ
Voltage
Wattage (Max. Power)
Wattage (RatedPower)
Current(RatedAmperes)
Watts
Volts
X Amperes
DC OUTPUT
Section 2. Specifications
1.4 EGSAA
120
1400
1200
10.0
60
12x5
TABLE 2-1. STANDARD SERIES SPECIFICATIONS
1.7 EGHAA
120
1700
1400
12.5
60
12x5
2.5 EGHAA
120
2500
2000
1 6.7
1 20
12x10
EN GlNE DETAILS
EngineSpeed (RPM)
EngineOil Capacity
Quarts (Litres)
Spark PlugGap
Inches(Millimeters)
StartingSystem
4.0 EGHAB
1201240
4000
3500
29.2/
1 4.6
3600
0.58 (0.55)
0.039 (1
.O)
Recoil
5.0 EGHAB
120/240
5000
5000
41.6120.8
GENERATOR SET DETAILS
Dry Weight
Pounds(Kilograms)
Dimensions
- Inches(mm)
Length
Width
Height
FuelTank Capacity
Gallons(Litres)
OperatingHours
At ContinuousPower
3600
0.95 (0.9)
0.028
(0.7)
Recoil
130 (59)
26.8 (681)
19(483)
21
3 (541)
1.58 (6)
3.3
70 (32)
23.5 (597)
16(406)
18.3 (465)
0.8 (3)
2.2
3600
1.16 (1.1)
0.039
(1 .O)
Recoil
170 (77)
28 (711)
21.25 (540)
24.75 (629)
2.1 (8)
4.4
3600
0.63 (0.6)
3600
0.63 (0.6)
0.028 (0.7)
Recoil 0.028
(0.7)
Recoil
75 (34)
23.5 (597)
16(406)
18.3 (465)
0.95 (3.6)
2.5
85
(39)
23.5 (597)
16(406)
18.3 (465)
0.95 (3.6)
2.3
SpecificationsSubject to Change Without Notice. 11-89.
2-1

TABLE 2-2. PRO SERIES SPECIFICATIONS
MODEL
GENERATOR DETAILS
AC OUTPUT-60 HERTZ
Voltage
Wattage
(Max Power)
Wattage
(Rated Power)
Current (Rated Amperes)
DCOUTPUT
Watts
VoL X Amperes
25 EGHAA 4.0 EGW
120 1201240
2500
' 4Ooo
2000 3500
1 6.7 292114.6
120 120
12x 10 12x
10
ENGINE DETAIU
Engine Speed (RPM)
Engine Oil. Capacity
Quarts
(Lib'es)
spark Piug.Gap
inches
(Millimeters)
Starting system
40 EGHEB
1201240
m
35M)
292114.6
120
12x10
3600
0.95 (0.9)
0.w (0.7)
Uectric/Recoil
3600
5.0 EGHAB 5.0 EGHEB 6.0 EGHEB
1201240 1201240 1201240
5ooo
5ooo 6ooo
5ooo 5ooo 5500
41.6120.8 41.6120.8 45.81229
120 120 120
12x10 12x10
, 12x 10
3600 3600
3600
1.1 6 (1 .l) 1.16(1.1)
- 1.16(1.1)
01139 (1.0) 0.039 (1 .o)
0.039 (1.0)
ReCOil Uectric/Recoil Oecbic/Recoil
0.63 (0.6)
0.028 (0.7)
Recoil
3600
0.95 (0.9)
0.028
(0.7)
Recoil
GENERATOR SET DETAlLs
weight
Pounds (ffilogmms)
Dimensions - inches (mm)
L=m
Vuidth-
Height
FdTank capacity
Gallons (rjtres)
. OperatnghHoun
. AtCcmtinuousFWw
Bat$lyRequi-
&attery (Group U1)
Coldcrankingmps
(at 32'F [OOCD
I I I
2-2

Section 3. Operation
4
pGiEGG-1
EXHAUST GAS IS DEADLY!
Exhaust gases containcarbonmonoxide, an odorlessand colorlessgas. Carbon
monoxideispoisonous and cancauseunconsciousnessand death.
Symptoms of
carbon monoxidepoisoning can include:
0 Dizziness
0 Nausea 0 Muscular Twitching
0 Headache 0 Vomifing
0 Weaknessand Sleepiness
0 ThmbbinginTemples
0 lnabilify to ThinkCoherenUy
IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESESYMPTOMS, GET OUT
INTO THEFRESHAIR IMMEDIATELY. Ifsymptomspersisf, seekmedicalattention.
Shutdown fhe unif and donot operate untilif has beeninspected and repaired.
Protectionagainst carbon monoxide inhalation includesproper installationand
regular, ftequentvisualandaudibleinspections
of fhecomplete exhaust system.
1-PfEM
GENERAL
Thissectioncoversstartingandoperatingthegenerator
set. Itisrecommendedthattheoperatorreadthroughthis
entiresectionbeforestartingtheset
It isessentialthatthe
operatorbecomecompletelyfamiliarwiththesetforsafe
operation.
PRE-START CHECKS
Beforestartingthegeneratorset, besureithassufficient
oiland gasolineandthat itis generallyreadyfor opera-
tion.
Engine Oil
Checkthe engineoil levelfrequently. Keepthe level full
but do not overfill. See the Maintenancesection for oil
specifications and oil checking and changing
procedures.
Fuel
Select a well ventilated locationfor filling fuel tank. Do
not fill fuel tank when engine is hot or running. See
RecommendedFuelsectionfor fueltype. Fillfueltank
slowlytoa pointno higherthanoneinchbelowthetop
ofthefillerneckorto red
fill lineinsidetank(ifequipped).
If operatingthe generator seton aslight grade, reduce
the amount of gas used when filling
so gas does not
reachfillerneck.
Do notstoreortransportthegenerator
set withoutfirst removingthefuelfrom thefuel tank.
Gasolinepresentsthehazard of fireor
/BWAR"GI explosion fhat can result in severe
personalinjuryor death.
Do notoYeM1fueltank or fuel
overflow can result After filling fuel tank, securely
tightenfuelcap.
Do nottransport the generatorsetwith-
out first removing fhe fuelfromthe fuel tank.
Gasolinepresentsthehazardoffireor
lHGEEl exp/osion that can result in severe
personalinjuryordeath.Never
fill thefueltankwhenfhe
engine
is hotorrunning. Do not permit any flame,spark,
pilot lighf, cigareffe, or ofher ignition source near the
fuelsystem. Keep a type ABC fireexPinguishernearby.
Inspection
Givethegeneratorsetavisualinspectionfor loosebolts
and nuts,oil leaks, fuel leaks, andexhaust leaks. Repair
any problemsbeforestartingthe generatorset
RECOMMENDED FUELS
Use clean, fresh, unleaded or regular grade gasoline.
Using unleaded gasoline results in extended periods
between service, longer spark plug life, and reduced
carbonbuild-upinsidethe engine.
GROUNDING REQUIREMENTS
Localcodeenforcementmightrequirethatthegenerator
set
be electrically connected to a grounding electrode
(water pipe, earth-driven grounding
rod, etc.) during
operation.
A grounding lug is provided for
connecting the generator set to
a grounding electrode
conductor.See Figure
3-1.
1. If faulty elecfrical equipment is
connected
to the generator set, an
electricalshockhazard existsfhat can resultin severe
personal injuryor
deafh. Checkallelectrical eq@inent
forfrayedcordsorbreaks in iheinsukiimbefore ming=
2. Broperiy appiied sn$ mabf&ed gmmd tawk circuit
interrupters, oiten
required by bcal codes, can affcre!
additionalprotection against We hazard of electrical
shock.
3-1

AC RECEPTACLE
DC RECEPTACLE
STANDARD
25 EGHAA
M-1830-2
M-18344
FIGURE 3-1. TYPICAL PORTABLE GENERATOR SET CONTROL PANELS
3-2

CONTROL PANEL
This sectiondescribesthefunctionandoperation of the
generatorset controlsforall
of themodels. Somecontrol
featuresarenotavailableoncertainmodels. Revieweach
of the controldescriptionsthatapplytothe modelbeing
used. RefertoFigure
3-1 fortypicalcontrolpanelconfigu-
rations.Proceduresforusingthecontrolsforstartingand
operatingthe setare providedinthe followingsections.
Control Components
Engine On/Off Switch (Standard Series): Mounted on
the engine, allows engine starting when the On/Off
switchissettotheOn position.Whentheswitchissetto
the Off position, itstopsengineoperation.
On/Sfop Switch (Fro Series):Allows the engineto be
started any time that the switch is in the On position.
Stopsengineoperation when heldintheStopposition.
Start/On/StopSwitch(ElectricStartModels): Pushing
switch into the Start position begins engine cranking.
When enginestarts,releasetheswitchanditwill return
totheOnposition.To stoptheengine, holdtheswitchin
the Stop positionuntilthe enginestops running.
Make sure that the Start/Stopswitch is left in the Stop
positicn.
If theswitchisleftinthecenterOnposition,the
startingbattery
will slowly discharge.
The Starf/Stopswitch must be leff
in the Stop position when the
genset
is notinuseorthe battery willdischarge. Do
not leave the StarVStop switch in the center On
position whentheset is not inoperation.
Low Oil Light:
Indicates low engine oil level. Low Oil
Lightwillflashduringcrankingor
will flashduringoper-
ationandthegeneratorsetwillstopiftheengineoillevel
isbelowthe low working level.
Fuel Gauge: Indicates the present fuel level in the
generatorsetfueltank.
Voltmeter: IndicatesgeneratorAC outputvoltage.The
meterwill read
120 VAC circuitvoltage.
AC andDC CircuitBreakers: Provideprotectionforthe
generator from shortcircuitsor overloads.
FullPowerSwitch:Allows operatortoselectfull power
operation from the
120 VAC receptacles or shared
powerbetweenthe
120 VAC and 240 VAC receptacles.
Switch setting also affectsvoltmeter readings; refer to
voltmeterdescription.
Idlematic Switch: Automatic enginespeedcontrol.Inthe
On position,theengineoperatesatidlespeeduntilaload
is applied. The ldlematic automatically increases the
engineto full speedwhen a loadisapplied. This feature
reduces engine wear and conserves energy. Inthe
Off
positionthe engineoperatesatfull speed.
Additional Controls
Fuel klve:Controlsfuel flow toengine.Settingfuelvalve
to Open position allows fuel to flow to engine. Set fuel
valvetoclosedpositionwhen generatorset isnotinuse.
See Figure
3-2.
ChokeLever: Restrictsairflowtothecarburetorforstart-
inga coldengine.
See Figure3-4.
Speed ControlLevers Sets engine speed (Figure 3-3).
This levershould be maintainedinthe highspeed (“H”)
positionat alltimes. Periodically check setting to make
sure itisinthe proper position.
START1 NG
Aftercheckingthegeneratorsetasdescribed in thePre-
StartChecksanddisconnectingallloadsfrom
the gener-
ator set, follow each of thesteps insequence.
lnhalafionofexhaustgas can result in
k%!!%l severe personal injury or death. Do
not
operate thegenerator set inpoorly venfilatedareas
suchas indoors, insidetanks, confinedareas, depres-
sions,
or anyarea whereexhaust gasesmightaccumu-
late. Locatetheexhaust
oullet so fhatexhausfgaseswill
not accumulateduringoperafion.
Due
to the danger of severepersonal
injury or d@h,
do not operate fhe
generator set inhazardous areas where itmight ignite
gases, combustibles,or explosive materials.
Generator setspresentthehazard of
electrical shock that
can result in
severe personal injury or death. Never expose the
generafor set
to rain, snow, or similar wet conditions
when operating.
Themuffler becomes veryhot during
andaftergenerator set
operafion and
can cause severe burns. Do not touchhotmuffler.
The voltage surge at start-up
can
-1 damage appliances (Tv sets, micro-
wave ovens, computes, etc.). Always disconnect all
loads before
sfarting thegenerator set.
3-3

I
-\,
FS-1627
T.8 GW.
i
I
I
1
i
-.
L
H 1
Y-1837
1.7- 4.0 EGH
FS-1828-1
1.7 - 4.0 EGH
FIGURE 3-3. SPEED CONTROL LEVER
3-4

Electric Start Models
1. Openthefuel valve (Figure 3-2).
2. Check to be sure that the speed controlfever is in
the highspeed (“HI’) position(Figure3-3).
3. Set the choke leverto the CLOSE position(Figure
3-4). If engineiswarm from previousoperation,do
notclosethe choke.
4. Start the engine by pressing the Start/On/Stop
switch
to theSTART position.Releaseswitchwhen
engine starts and it will returnto the On position.
Open the choke lever as the engine warms up.
Allowtheenginetowarmupforthreetofiveminutes
beforeapplyingaload.Thevoltmeteronthecontrol
panelwill indicategenerator outputvoltage.
If theoilwatch lampflashesduringcrankingorrunning,stopthe
engineandcheck the
oil level. Add oil as recommendedinthe
Maintenance
section.
5. Proceedto Adding Loadsinthissection.
Manual Start Models
1. Openthe fuel valve (Figure3-2).
2. Check to besurethatthespeed control lever isin
thehighspeed
(“H) position(Figure 3-3).
3. Setthe choke lever to the CLOSE position(Figure
3-4). Ifengine iswarm from previousoperation,do
. not closethe choke.
4. Makesurethe engineswitch isinthe On position.
5. Withonehandonthegeneratorsettosteady it, grip
therecoilhandleandpulloutsmoothlyandquickly.
Repeatas necessary.Whentheengine
starts, open
thechokelever as the enginewarms up. Allow the
enginetowarm up
for threeto five minutesbefore
applyinga load.
lftheoilwatch lampflashesduringcranking orrunning,stopthe
engineandchecktheoillevel. Add oilasrecommendedin
the
Maintenancesection.
6. ProceedtoAdding Loadsinthis section.
1.4 EGSAA
M-1841-1
1.7 - 4.0 EGH
&I842
5.0 - 6.0 EGH
FIGURE 3-4. CHOKE LEVER
3-5

ADDING LOADS
Follow the appropriateprocedurefor adding either AC
loadsor
DC loads.
Continuous overloading can cause
kiBi3I high operating temperatures that
could damage fhe generator set. Keep the load within
thenameplaterating.
Adding AC Loads
1. Notethe ratedoutput of thegeneratorset (fromthe
generator set nameplate or the Specification
section).
2. Check the load ratingof each
of the itemsthat you
planto connectto the generator set Table 3-1 lists
typical wattagesfor commonappliancesandtools.
3. Add the wattages of the itemsyou want to operate
andmakesurethatthetotalwattageisnotmorethan
the generator set rated output Note the following
example.
Example: For model 2.5 EGHAA with a maximum
poweroutputof
2500 wattsandaratedoutputof2000
watts, it would be possible to operate a portable
heaterratedat
1500 watts, a drill ratedat 400 watts,
anda
100 watt light. Ifyou also wished to operatea
circlesawratedat
900 watts it wouldbenecessaryto
disconnecttheheaterwhile
you areusingthecircle
Saw.
If amotorloadandanotherloadtotalveryclosetothe
ratedoutputof thegeneratorset, startthemotorload
first and allow itto operate at normal speed before
connecting the other load. Motor loads consume
muchmorepowerduring
start upthantheydowhen
theyarerunning(somemotorsdraw
up tothreetimes
their runningload).
High Altitudes
Maximum power decreases roughly four percent for
each 1000feet (310 m) above sea level (after the first
1000feet).
If operation is degraded by altitude above
2000 feet (620
m), calculatealtitude deratingto deter-
mine maximumAC loadcapacity.
Models wifh Full Power Switch: Set the full power
switchtothe positionthatcorrespondstotheelectrical
requirements
of your equipment (Figure 3-5). Set the
switch to the 120V Only setting to use the 120-volt
duplex receptacleorthe 120-volttwist-lockreceptacle
onlyortothe120/240Vsettingtousethesereceptacles
andthe 120/240V twist-lock receptacle.
TABLE 3-1. TYPICALWATTAGE REQUIREMENTS
Typical
BenchGrinder (8 in.) .................... 1400
CircleSaw (7-1
/4 in.) ................... 900
CoffeeMaker(drip). ..................... 850
CoffeePercolator ....................... 850
Drill(3/8 in.). ........................... 400
ElectricWater Pump
.................... 550
Range(smallburner) .................... 1275
Range(largeburner)
.................... 2400
Sump Pump
............................ 350
TV(B&W)
............................. 60
TV(Color) .............................. 200
Electrical Equipment Running Watts'
PortableHeater.. ....................... 1500
Refrigerator ............................ 600
Trimmer (12 in. heavyduty)
..............
500
*See textfor typicalstartingwatts of motor loads.
AC 12Ov
ONLY
qjJ t
+
AC
120124ov
M-1843
FlGURE 3-5. FULL POWER SWITCH
Models wifh /d/mafic: MovetheldlematicswitchtoOnif
you want the idlematicfeature to operate (Figure 3-6).
Thisfeatureautomaticallycontrolsenginespeed
so it will
operateatidlespeedwithno-loadandfullspeedwhena
loadisconnected.If you do notwantto usethisfeature,
keeptheswitch inthe
Off position.
Keeptheldlematic Switchat O?fifLerewill bea lot of mall intmpted
loads or loads under 0.8 amperes.
3-6

ON
OFF
M1W
FIGURE 3-6. IDLEMATIC SWITCH
4. Connectthe AC loadsto the receptacle(s)on the
controlpanel. Makesurethecordandplugconnec-
tor havegroundterminals.
Electrical shock can cause
severe personal injury or death.
Cordand plug equipment
must havea groundfer-
minal
to provide additionalprotection.
Adding DC Loads
Connect the DC loads to the DC receptacle on the
control panel. Make sure load wires positive
(+) and
negative
(-) matchwith the polaritiesatthe receptacle
on the controlpanel. Referto the Specificationsection
for maximumDC output currentat 12volts.
Batteriesemit ahighly explosivegas
thatcanbe ignitedby elecfricalarc-
ing, smoking,or other ignifionsource. Whencharging
batteries, connect cables
fo the battery before con-
nectingcables
to thegenera for set. Thiswillreducethe
risk of arcingat thebatterythat could causean explo-
sion. When battery charging
is complefe, remove the
cableatfhegenerator setbeforeremovingcablesfrom
the battery.
Do not use AC receptacles while using DC power on the following
models:
1.4 EGSAA, 1.7 EGHAA, 2.5 EGHAA,
CIRCUIT BREAKERS
If eitheraDCorAC circuitbreakeropens,checktosee if
the generatorset isoverloaded. If so, removesomeof
theloadfromthegeneratorset. Resetthecircuitbreaker
by pushing inthe indicator(reset after waiting
a min-
imum of 10secondsafter tripping).
Ground-Fault Circuit-Interrupter
Somemodelsare equippedwitha120-voltGFCl outlet.
These outlets are intended for user protection. The
GFCl deenergizesthe circuit
it is connected to when a
currenttogroundexceedsapredeterminedvalue.Ifthe
GFCl RESET buttontrips during operation,disconnect
mentfor defects.
L
theload,stop thegeneratorset, andinspecttheequip-
TesttheGFCl monthlyby startingthegeneratorsetand
pressingthe
TEST button.IftheRESETbuttonpops out,
push the RESET button back in to returnthe outletto
normal operation.
If the RESET does notpop out, the
GFCl mustbereplaced.
OIL WATCH INDICATOR
TheOilWatchflashesduringcranking if theoillevel is
low. It alsoflashesandstopsthegeneratorset ifthe set
isrunningandtheoillevelreachesthe low workinglevel
of the OilWatch. See Figure 3-7 for typical OilWatch
illustration. Add oil as recommended
in the Mainte-
nancesection beforeattemptingto restart
UPPER
OIL UMIT
FIGURE 3-7. TYPICAL OIL WATCH
STOPPING
1. Removeall loadsfromthe generator set
2. Let the generator set run for three
to five minutes
without a loadto allowthe engineto cooldown.
3. Closethefuelvalve.
Gasolinepresentsthehazard of
fire
or explosionthat canresult
in severe personal injury
or death. Always close
the fuel valve when the engine is not in use
to
reduce therisk of fuel leakage.
4. Stop the generator set by pressing the Start/Onl
Stop or On/Stop switch to Stop or by turning the
Engine On/Off switch to
Off, depending on the
model.
MakesurethattheStart/On/Stopswitchisleftinthe
Stop position. If the switch
is left in the center On
position,the startingbattery
will slowly discharge.
HIGH/LOW OPERATINGTEMPERATURES
Thegeneratorsetwilloperatesatisfactorilyinbothhigh
andlowtemperatures.Usetheoil recommendedinthe
Maintenance section for the expected temperature
conditions.
HighOperatingTemperatures
1. See that nothing obstructsthe airflow to and from
2. Keep the engine cooling fins clean. Air housings
thegenerator set.
should be properlyinstalledand maintained.
LowOperatingTemperatures
1. Usefreshgasolineandkeepthetankfilledto avoid
2. Keepthe spark plug clean and correctly gapped.
condensation.
3-7

EXTREMELY DUSTY OR
DIRTY CONDITIONS
Observe the following procedures when operating the
generatorset inextremelydusty or dirty conditions.
1. Keep thegeneratorset clean and do notallow dust
2. Cleanthe air cleaner moreoftenthan shown inthe
and dirtto accumulate.
maintenanceschedule.
PROBLEM
FAILSTO CRANK
(ELECTRICSTART MODELS)
GENERATOR SET EXERCISE
Infrequentoperation of the generator set can result in
moisturecondensationintheengineanddifficultstarting.
Moistureaccumulatesbecausethe enginedoes not run
often enough to reach normal operating temperature.
This moisturecan causedamage to the engine.
To preventmoisturedamage, runthegeneratorset at 50
percentcapacity (see Specifications section) two hours
everyfourweeks.
A longexerciseperiodismoreeffective
thanseveralshort periods.
.
>
PROBABLE CAUSE SOLUTION
1. Low Battery
2. Bad battery connection.
1. Check batteryelectrolytelevelandcharge.
2 Cleanandtightenall batteryandcableconnections.
3. Keepoilandgas indust-tight containerssuitablefor
storage
of fuels.
~~ ______~
1. Low battery.
2. Badbatteryconnection.
3. Oilistoo heavy.
4. Load is connected.
TABLE 3-2. TROUBLESHOOTINGGUIDE
~~~ ~ ~~ ~ ~~
1. Check batteryelectrolytelevelandcharge.
2 Cleanandtightenallbatteryandcableconnections.
3. Replace with lighteroil.
4. Always disconnectloadwhilestarting.
Thefollowingtroubleshootingguidecanbeusedforbasicproblemdiagnosis. If theserecommendationsdonotresolve
the problem,contactan authorized Onanservicecenter.
Many troubleshooting procedures presenf hazards that can result in severe personal injury or
death.On/yqualifiedservicepersonnel withknowledgeof iuels,electricityandmachineryhazards
shouldperform service procedures. Review safety precautions
on inside coverpage.
1. Outoffuel.
2. Fuelsupplyvalveclosed.
3. Carbondepositson spark
4. Lowoil level.
Plug-
1. Add fuel.
2 Fullyopenfuelsupplyvalve.
3. Removeand cleanorreplace.sparkplug.
4. Add oil as necessary.
CRANKS
SLOWLY
(ELECTRICSTART MODELS)
1. Chokeclosed.
2. Dirty air filter.
3. Richfuelmixture.
1. Openchoke.
2. Clean or replaceair filter.
3. Contactan Onanservicecenter.
ENGINEWONT START
1. Loose or worn sparkplug
lead.
2. Faultysparkplug.
3. Dirtyfuelfilter or generator
set attoo
steep of an angle.
4. Governor out of adjustment
or leanfuel mix.
1. Checksparkplug lead connection.
2. Removeand clean or replacespark plug.
3. Checkfuelfilterandgenerator set angle.
4. Contactan Onan servicecenter.
EXHAUSTINGBLACK
SMOKE
1. Open DC circuitbreaker
due toan overload.
1. Removeallloads, resetcircuitbreaker,checkfor an overload or shortec
battety. Do notexceedgenerator setratedloadspecifications.
UNITRUNS THEN STOPS
UNIT RUNS BUTSURGES
1. Outoffuel.
2. Lowoil level.
3. Excess oil.
1. Addfuel.
2 Add oil.
3. Reduceoil level.
NO AC OUTPUTVOLTAGE
1. Open AC circuitbreaker 1. Removeallloads, re-set circuitbreaker, checktoolsorappliancesbeing
usedfor defects. Do notexceedgenerator set ratedloadspecifications.
I duetoan overload.
1
NO DC OUTPUT VOLTAGE
Y
A
3-8

Section 4. Maintenance
4
GENERAL
Establishandadhereto adefiniteschedulefor mainte-
nanceandservice.
If thegeneratorset will besubjected
to extremeoperatingconditions,consultanOnanAuth-
maintenanceschedule.Keepanaccurate
log ofallser-
viceand maintenancefor warranty support.
Perform all maintenance at the number of operating
hours indicated. Use the schedule to determine the
maintenancerequired,then refer tothefollowing sec-
tionsfor the maintenanceprocedures.
Accidental starting of the generator
raWARNlNGI set during maintenance can cause
Severe personal injuO' Or death* Before performing
generatorsetstarting batteqcables.Remove theneg-
ative
(-) cable firsttoreducetherisk ofarcing.
A hot generaforsetcan causesevere
burns. Always allow the generafor
set to cool beforeperforming any maintenance or
service.
L
maintenance,disconnectthesparkplug wire fromthe
orized Service Center and determine an appropriate
spark plug. Electric start models; disconnect both
TABLE 4-1. PERIODICMAINTENANCESCHEDULE
SERVICETHESE ITEMS
GeneralInspection
Check Oil Level
ChangeCrankcaseOil
Clean Air Filter
SERVICE INTERVAL
EVERY EVERY EVERY EVERY EVERY
8 HOURS 50 HOURS 100 HOURS 200 HOURS 500 HOURS
X
$93
x3
1 - Checkfor loose parkand for oil and fuel leaks. Checkexhaustsystem audibly andvisuallywith generatorset runingand repair any leaks
immediately.Replacecorrodedexhaustandfuel linecomponentsbefore
leaks occur.
2 Performafter first 20 hours of operationonnewsets.
J - Performmoreoften in extremelydusty conditions.
4 - Performevery 50 hourson 1.4 kW model.
5 - Performon 4-, 5-, and 6-kW ProandStandardmodelsonly.
6 - Haveyour Onan servicecenterperform.
a
4- 1

GENERAL INSPECTION
Cleanthegeneratorsetand performageneralinspec-
tionbeforeusingtheseteachdayoratleasteveryeight
operatinghours. Check for loosepartsor any signs of
mechanicaldamage.Startthegeneratorset,andcheck
for visible and audible irregularities. Examine the
exhaust system for leaks and inspect the fuel supply
line,filter,tank,andfittingsforleaks.Ifanyproblemsare
found, havethemcorrectedimmediately.Replaceworn
or damagedparts beforeleaksoccur.
Fuel presents the hazard of fire or
-1 explosion that can result in severe
personalinjury
or death. If anyleaksaredetected,have
themcorrectedimmediately.
Do not start generatorset
untilgas and fumesarepurged from the area.
LUBRICATIONSYSTEM
Theengineoilwasdrainedfromthecrankcasepriorto
shipment. Beforethe initial start, the engine must be
filled with oil
of the recommended classification and
viscosity. RefertotheSpecificationssectionforthelub-
ricatingoilcapacity.
CheckingEngine Oil Level
Be sure the engine crankcase is filled with oil. Make
surethat the generator set
is restingon a levelsurface
whencheckingoillevel.Ifaddingoilbetweenchanges,
use the same brand and viscosity; different brands
might not be compatible when mixed. See Recom-
mendedEngineOil
in thissection.
Add oilvery slowly untilthefull levelisreached,butdo
notoverfill.Too muchoilcancausefoamingandengine
shutdown. Always replacetheoilcapsecurelyto pre-
vent leakage. Referto Figure
4-1.
Hot oil can cause severe personal
k@!@%l injury. Do not check the oil level
whilethegenerator set
is running:oil may blow out of
. the oil fill tube.
Checktheoil levelon allmodelsexcept 5.0 and 6.0 kW
modelas follows:
*
1. Remove oilcap andobserveoil level.
2. Oil levelshould appear atthetop of the oil port.
3. Add oil untiloillevelreachesthetopof theoilport.
Checktheoillevelon
5.0 and 6.0 kWmodelsasfollows:
Removeoillevelindicatorand wipewith cleanrag.
Insert
oil levelindicator intooilfill and push down
untilseated.
Remove oil level indicatorand check oil level on
indicatorstem.
Addoiluntiloillevelreachesuppermarkonindica-
tor stem.
ChangingEngineOil
Figure4-1showsthelocation of theoildrain. Industyor
dirty conditions, change the oil more frequently than
specifiedin
the MaintenanceSchedule.
Runtheengine untilwarm beforedrainingthe oil.
.
Hot oil can cause severe burns if
laWAR"G1 spilledorsplashedonskin. Keepfin-
gers and hands clear when removing oil drain plug,
and wearpmtecfive
clothing.
To drain oil, place a pan under the oit drain plug.
Remove oil plug and allow oil to drain from engine.
Replace
oil plug securelytopreventteakage.
L . CAP
FIGURE 4-1. OILLEVELCHECK
4-2