Operator`s Manual
Contents
1. FIGURE 5 FUEL VALVE ALL GENSETS FS1828 1 HIGH START ENGINE CHOKE LEVER SPEED CONTROL LEVER FIGURE 6 SPEED CONTROL AND CHOKE OPERATION GENSETS 4 0 KW AND BELOW TOP VIEW FUEL TANK REMOVED TO SHOW LEVER POSITIONS MANUAL CHOKE LEVER FIGURE 7 CHOKE OPERATION 5 0 KW AND 6 0 KW GENSETS ADDING LOADS Continuous overloading can cause high operating temperatures that could damage the generator set Keep the load within the nameplate rating Adding AC Loads 1 Note the rated output of the generator set from the generator set nameplate or the Specifica tions section 2 Check the load rating of each load Table 1 lists typical wattages for common appliances and tools 3 Add the wattages of the loads and make sure that the total wattage is not more than the gen set rated output Note the following example Example The 3 5 kW models have a maxi mum power output of 3500 watts and a rated output of 3000 watts A 1500 watt heater 900 watt circular saw 500 watt drill and a 100 watt light could all be operated at the same time To operate a second saw rated at 900 watts it 10 would be necessary to disconnect the 1500 watt heater If a motor load and another load have a com bined wattage close to the rated output of the generator set start the motor load first and let it run at normal sp2. Battery Requirements Battery Group U1 Cold Cranking Amps at 32 F 0 C 26 60 120 240 5000 5000 41 6 20 8 12 VDC 120 W 10 A Elite E140H 3600 Gasoline 1 0 qt 0 95 L 0 035 in 0 89 mm Intake and Exhaust 006 010 in 0 15 0 25 mm 23 Recoil 14 bhp max 390 175 Ib 79 kg 29 2 742 22 5 572 28 3 719 8 gal 30 3 L 10 60 120 240 5000 5000 41 6 20 8 12 VDC 120 W 10 A Elite E140H 3600 Gasoline 1 0 qt 0 95 L 0 035 in 0 89 mm Intake and Exhaust 006 010 in 0 15 0 25 mm 23 Electric Recoil 14 bhp max 390 185 Ib 84 kg 29 2 742 22 5 572 28 3 719 8 gal 30 3 L 10 12 volt 235 6 0 EGHEB 60 120 240 6000 5500 45 8 22 9 12 VDC 120 W 10 A Elite E140H 3600 Gasoline 1 0 qt 0 95 L 0 035 in 0 89 mm Intake and Exhaust 006 010 in 0 15 0 25 mm 23 Electric Recoil 14 bhp max 390 205 Ib 94 kg 29 2 742 22 5 572 50 HZ GENSETS 20EGHAM 3 5EGHEM 5 0EGHEM GENERATOR DETAILS AC Output Frequency Hertz Voltage Wattage Max Power Wattage Rated Power Current Rated Amperes DC Output ENGINE DETAILS Engine Type Engine Speed RPM Fuel Engine Oil Capacity Spark Plug Gap Engine Valve Lash Ignition Timing BTDC fixed Starting System Horsepower Displacement cc GENERATOR SET DETAILS Dry Weight Dimensions Length Inches Width Inches Height Inches F
3. 1000 1500 600 1000 1000 1500 See text for starting watts of motor loads Adding DC Loads Connect the DC loads to the DC receptacle on the control panel Make sure that polarities are correct when attaching positive and negative leads Refer to the Specification section for maximum DC output current at 12 volts NOTE The Idlematic switch must be off when only DC loads are connected NOTE Do not leave DC load connected to the DC re ceptacle with the generator set not operating Batteries emit a highly explosive gas that can be ignited by electrical arcing smoking or other ignition source When charg ing batteries connect cables to the battery be fore connecting cables to the generator set This will reduce the risk of arcing at the battery that could cause an explosion When battery charging is complete remove the cable at the generator set before removing cables from the battery Always remove the negative cable before the positive cable and replace it after the positive cable Do not connect AC loads while using DC power on 2 0 kW model CIRCUIT BREAKERS If an AC or DC circuit breaker opens check to see if the generator set is overloaded If so remove some of the load from the generator set Reset the circuit breaker by pushing in the indicator reset after wait ing a minimum of 10 seconds after tripping GROUNDING Receptacles Generator set receptacles are internally grounded to t
4. W 12 VDC 120 W 12 VDC 120 W 12 VDC 120 W 10 A 10 A 10 A 10 A ENGINE DETAILS 120 12020 120 240 120 240 po eus GH280 3600 Gasoline Engine Oil Capacity 0 95 at 0 91 0 7 mm 0 7 mm 0 7 mm Engine Valve Lash Intake and Intake and Intake and Exhaust Exhaust Exhaust 0 002 0 0039 in 0 002 0 0039 0 002 0 0039 0 05 0 10 mm in in 0 05 0 10 mm 0 05 0 10 mm Ignition Timing BTDC 21 25 29 fixed Starting System Electric Recoi Horsepower 5 5 bhp max 9 0 bhp max 9 0 bhp max Displacement 63 Tob 50 pus 268 687 22 559 22 559 i 6 6 L 1 Height Inches 24 6 625 24 6 625 24 6 625 Fuel Tank Capacity 6 5 gal 24 6 L 6 5 gal 24 6 L 6 5 gal 24 6 L Rated Output Operating 13 Hrs Battery Requirements Battery Group U1 Cold Cranking Amps at 32 F 0 N eo 3 ew Op 60 HZ GENSETS 5 0 EGHAB GENERATOR DETAILS AC Output Frequency Hertz Voltage Wattage Max Power Wattage Rated Power Current Rated Amperes DC Output ENGINE DETAILS Engine Type Engine Speed RPM Fuel Engine Oil Capacity Spark Plug Gap Engine Valve Lash Ignition Timing BTDC fixed Starting System Horsepower Displacement cc GENERATOR SET DETAILS Dry Weight Dimensions Length Inches Width Inches Height Inches Fuel Tank Capacity Rated Output Operating Hours
5. eight hours of operation 1 16 Inspect fuel lines and fittings for leaks Repair leaks immediately Look and listen for exhaust system leaks while the engine is running Look for cracks and se vere rusting in the muffler and tailpipe Have all leaks repaired before continuing to operate the equipment Hot exhaust parts can cause severe burns Allow the engine time to cool before servicing the exhaust system Check the engine for dirt and debris and clean the flywheel air inlet screen and cylinder cool ing fins as necessary A clogged flywheel air inlet screen or dirty cooling fins can cause over heating and engine damage Keep the cool ing fins and air inlet screen clean Check the engine oil level The equipment must be parked on a level surface and the en gine stopped To get an accurate reading wait a minute or so to allow the oil to settle in the crankcase if the engine has been running Crankcase pressure can blow hot engine oil out the fill tube causing se vere burns Always stop the engine before removing the oil fill cap Gensets 4 0 kW and below Remove the oil cap and observe the oil level The oil level should appear at the top of the oil port Gensets 5 0 kW and above Pull the dipstick up to remove it from the fill tube Wipe the dip stick clean push it back into the oil fill tube until the cap seats and then withdraw it to check the oil level If the oil level is low add API C
6. servicing the the muffler Inspect the muffler for corrosion and physical de fects Operate and generator set and check for ex haust leaks and noisy operation Replace a noisy or defective muffler before using the generator set The exhaust spark arrester requires periodic clean ing for safe operation and to maintain maximum effi ciency Consult the maintenance schedule for rec ommended cleaning intervals Allow the generator set to cool down before servicing the muffler Remove the spark arrester screen Figure 15 in spect for damage and replace if defective To clean lightly tap the screen and clean any deposits with a wire brush Also use a commercial solvent if necessary Allow screen to dry then reassemble and attach securely AWARNING Most part cleaning solvents are flammable and misuse can result in severe per sonal injury or death Follow the manufactur er s recommendations Work in a well venti lated area and do not allow any spark flame pi lot light cigarette or other ignition source near TAILPIPE the generator set Keep a fire extinguisher rated ABC near work area FRONT VIEW MUFFLER SIDE VIEW SPARK ARRESTER EXS1152 2 MOUNTING SCREW FIGURE 14 SPARK ARRESTER CLEANING GENSETS 4 0 KW AND BELOW LOOSEN MOUNTING SCREW TO REMOVE SPARK ARRESTER FIGURE 15 SPARK ARRESTER CLEANING 5 0 AND 6 0 KW GENSETS 22 CLEANING THE GENERATOR SET Remove s
7. 28 Improper service or replacement of parts can result in severe personal injury and equipment damage Service personnel must be qualified to perform electrical and or mechanical service WARNING A The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Introduction This manual describes the Onan Pro series porta ble generator sets Study this manual and comply with all warnings and cautions Using and maintain ing the set correctly will result in longer set life bet ter performance and safer operation The Onan warranty form generator and control only comes with the set manual A service manual may be ordered through an Onan dealer or distribu tor MODEL IDENTIFICATION When contacting an Onan dealer for parts or ser vice provide the model and serial numbers from the genset nameplate Figure 1 Write the model and serial numbers in the boxes provided in Figure 1 to make them easy to find WRITE MODEL AND SERIAL NUMBERS HERE MODEL NUMBER SERIAL NUMBER SET NAMEPLATE LOCATED ON OPPOSITE SIDE OF GENERATOR ELECTRIC GENERATOR IMPORTANT WHEN WRITING ABOUT SERVICE OR PARTS GIVE MODEL AND SERIAL NUMBER WATTS MAXIMUM RATED AMPS mateo SERIAL NUMBER PLATE FIGURE 1 GENSET IDENTIFICATION FUEL FILL RECEPTACLE CONTROL RECOIL aan PANEL STARTER BATTER
8. COVERED AC RECEPTACLES 50 HZ GENSETS FIGURE 3 CONTROL PANEL GROUND SOCKET LP N L 120 VAC TO 120 VAC TO GROUND GROUND UK RESIDENTIAL RECEPTACLE GREY 13 AMP 220 240V N L 120 VAC TO 120 VAC TO GROUND GROUND E GROUND SOCKET EUROPEAN INDUSTRIAL RECEPTACLE BLUE 16 220 240V E GROUND PIN L 120 VAC TO GROUND N NETRAL SOCKET L O 120 VAC TO E GROUND GROUND SOCKET UK INDUSTRIAL RECEPTACLE YELLOW 16 AMP 110 130V GROUND CONNECTION 120 uc TO GROUND 120 JAG TO GROUND GROUND CONNECTION GERMAN RESIDENTIAL RECEPTACLE GREY 16 AMP 220V N 120 VAC TO GROUND FRENCH RESIDENTIAL RECEPTACLE GREY 16 AMP 220V FIGURE 4 RECEPTACLE VARIATIONS 50 HZ GENERATOR SETS STARTING PROCEDURE After checking the generator set as described in the Pre Start Checks and disconnecting all loads from the generator set follow each of the steps in se quence Inhalation of exhaust gas can result in severe personal injury or death Do not oper ate the generator set in poorly ventilated areas such as indoors inside tanks confined areas depressions or any area where exhaust gases might accumulate Locate the exhaust outlet so that exhaust gases will not accumulate during operation Due to the danger of severe person al injury or death do not operate the generator set in hazardous areas where it might ignite
9. CTION If you are unable to exercise the generator set reg ularly and the set will notbe in use for more than 120 days the following procedure is recom mended Failure to provide out of service protec tion can result in difficult starting rough engine op eration and reduced engine life Preparing Generator Set For Storage 1 Add a fuel preservative and stabilizer such as OnaFresh to the fuel supply Follow manufac turer s instructions for using the fuel additive Run the generator at 50 percent load see Specifications section for 30 minutes Fuel additives can cause a risk of personal injury Read and follow manufacturer s instructions 2 Disconnect the load Turn the fuel supply valve off and remove the air filter As the gen erator set runs out of fuel squirt fogger such as OnaGard into the carburetor intake then reassemble the air filter OnaGard is a trademarks of Onan Corporation 3 When the generator set runs out of fuel and stops running remove the spark plug Squirt one tablespoon about 30 ml of clean engine oil into the spark plug hole Turn the engine over for several revolutions Replace the spark plug Pull the recoil starter handle out slowly until compression is felt Drain the oil base while still warm Refill the crankcase and attach a tag indicating viscos ity of oil used Hot oil can cause severe burns if spilled or splashed on skin Keep fingers and hands clear when removing o
10. E Operator s Manual Models EGHAM EGHEM EGHAA EGHAB EGHEB Portable Generator Sets Pro Series Printed in U S A 10 95 965 0100 Safety Precautions Before operating the generator set read the Operator s Manual and become familiar with it and your equipment Safe and efficient operation can be achieved only if the equip ment is properly operated and maintained Many accidents are caused by failure to follow fundamental rules and precau tions The following symbols found throughout this manual alert you to potentially dangerous conditions to the operator service per sonnel or the equipment ONY Weiss This symbol warns of immediate haz ards which will result in severe personal injury or death AWARNING This symbol refers to a hazard or unsafe practice which can result in severe personal injury or death CAUTION This symbol refers to a hazard or unsafe practice which can result in personal injury or prod uct or property damage Fuels electrical equipment batteries exhaust gases and mov ing parts present potential hazards that could result in severe personal injury Take care in following these recommended procedures FUEL AND FUMES ARE FLAMMABLE Fire explosion and severe personal injury can result from improper practices DO NOT fill fuel tanks with the engine running Fuel con tact with hot engine or exhaust is a potential fire hazard DO NOT SMOKE OR ALLOW AN OPEN
11. FLAME near the generator set or fuel tank DO NOT store or transport the generator set without first removing the fuel from the fuel tank DO NOT SMOKE while servicing batteries Lead acid bat teries emit a highly explosive hydrogen gas that can be ig nited by electrical arcing or by smoking EXHAUST GASES ARE DEADLY Engine exhaust contains CARBON MONOXIDE a dan gerous gas that is potentially lethal Avoid carbon monox ide inhalation by operating the generator set outdoors where exhaust gases can be discharged directly into the open air Do not operate the generator set in any type of enclosure that could allow exhaust gases to accumulate Direct ex haust gas away from areas where people are gathered and away from buildings or enclosures MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Before performing any maintenance on the generator set disconnect the spark plug wire and the starting battery negative cable on electric start sets to prevent acciden tal starting Keep hands away from moving parts Do not wear loose clothing or jewelry while servicing any part of the generator set Loose clothing and jewelry can become caught in moving parts Jewelry can short out electrical contacts and cause shock or burning Make sure that fasteners on the generator set are secure Tighten supports and clamps keep guards in position over fans drive belts etc f adjustments must be made while t
12. Y TRAY LOCATION SETS WITH ELECTRIC START ELECTRIC STARTER LOCATION OPTIONAL OIL FILL amp DIPSTICK 2 0 KW 2 5 KW 3 5 KW 4 0 KW GENERATOR SETS FUEL FILL RECEPTACLE CONTROL RECOIL STARTER ELECTRIC STARTER OIL FILL amp DIPSTICK pe TRAY 5 0 KW 6 0 KW GENERATOR SETS FIGURE 2 COMPONENT LOCATIONS FUEL RECOMMENDATIONS Use clean fresh unleaded gasoline with an octane rating anti knock index of 87 or higher During some times of the year only mandated oxy genated gasolines may be available these are ac ceptable for use but not preferable Using leaded gasoline will result in the extra maintenance re quired for removing combustion chamber and spark plug deposits Do not use gasoline or gaso line additives de icers containing methanol which can be corrosive to fuel system components CAUTION Do not use gasoline or gasoline ad ditives containing methanol because methanol can be corrosive to fuel system components Avoid using highly leaded gasolines and lead additives because of the extra engine mainte nance that will be required Gasoline is highly flammable and can cause severe personal injury or death Do not smoke if you smell gasoline or are near fuel tanks or gasoline burning equipment or are in an area sharing ventilation with such equip ment Keep flames sparks pilot lights electri cal arcs and arc producing equipment and all other sources of ignition well aw
13. an cause se vere engine damage Keep the oil level be tween the Full and Add marks on the dip stick 5 Reconnect the spark plug and battery 6 Start the engine and run it for a short time while checking for oil leaks around the drain plug and oil filter Do not overtighten tighten only as nec essary to eliminate leaks Used oil is harmful to the environment Pour the used oil into a sealed container and deliver it to the nearest recycling center LS1122 OIL OIL PORT CAP FIGURE 9 OIL CHECK REFILL GENSETS 4 0 KW AND BELOW 17 CONTROL SIDE OF ENGINE OIL FILL AND DIPSTICK SERVICE SIDE REAR OF ENGINE 90 DEGREE OIL FILTER ELBOW OIL DRAIN FIGURE 10 OIL CHECK REFILL FILTER REPLACEMENT 5 0 KW AND 6 0 KW GENSETS AIR CLEANER MAINTENANCE Gensets 4 0 kW And Below 1 Carefully remove the air cleaner cover and the air cleaner element See Figure 11 2 Remove foam wrapper and wash in detergent and water Dry foam wrapper thoroughly Use low pressure air on the inside of the paper ele ment to remove dust and dirt Replace paper element at every
14. ay ENGINE OIL RECOMMENDATIONS Use premium quality motor oil Look for the API American Petroleum Institute classification and use Class SG or SH oil also SG CD SG CE SH CD or SH CE Also look for the SAE Society of Au tomotive Engineers viscosity grade See the Oil Change description for the viscosity grade ap propriate for the temperatures expected Single grade SAE 30 oil is better when tempera tures are consistently above freezing Multigrade oils are better when wide temperature variations are expected STARTING BATTERIES A set with an electric starter requires a 12 volt start ing battery Prompt starting requires sufficient bat tery capacity and battery cable size Neither crank ing performance nor starter service life will be ade quate with an undersized battery See Maintenance and any instructions available from the battery manufacturer for battery mainte nance Note that as long as the set is run regularly the automatic battery recharging system on the en gine should maintain battery charge See OUT OF SERVICE PROTECTION under Starting and Run ning the Set regarding battery care during storage for prolonged periods EXHAUST SYSTEM EXHAUST GAS IS DEADLY Generator sets must never be operated inside buildings or other en closed spaces without ample fresh air ventilation Gensets used inside buildings or other enclosed spaces must be equipped with a leak free exhaust system that carries all exhaus
15. con nect the negative cable last to reduce the risk of arcing Apply a light coating of petroleum jelly or non conductive grease to battery con nections to retard corrosion 4 Maintain the electrolyte level by adding distilled water as needed to reach the split level marker in the battery The water component of the electrolyte evaporates but the sulfuric acid component remains For this reason only add water to a low battery 5 Use a battery hydrometer to check the specific gravity of the electrolyte in each cell A battery 20 should be charged if the specific gravity mea sures less than 1 215 When charging the bat tery avoid overcharging Stop charging bat tery when the electrolyte specific gravity reach es 1 260 at approximately 80 F 27 C FUEL FILTER REPLACEMENT Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Do not permit any flame spark pilot light cigarette arcing switch or equipment or other ignition source near the fuel system In spect for fuel leaks any time service is per formed on the fuel system Keep a fire extin guisher rated ABC near work area Clean or replace the fuel filter at the interval recom mended in the Maintenance Schedule or if perfor mance problems occur and bad fuel is suspected Gensets 4 0 kW And Below 1 Turn the fuel supply valve to the closed position and allow the set to operate until it runs out of fuel Let the
16. d Avenue N E Minneapolis MN 55432 763 574 5000 Fax 763 528 7229 Cummins and Onan are registered trademarks of Cummins Inc
17. eed before connecting the other load Motor loads consume much more power during start up than they do when they are running some motors draw up to three times their running load 4 Connect the AC loads to the receptacle s on the control panel Make sure the cord and plug connector have ground terminals Electrical shock can cause severe personal injury or death Cord and plug equip ment must have a ground terminal to provide additional protection High Altitudes Maximum power decreases roughly four percent for each 1000 feet 310 m above sea level after the first 1000 feet When operating the generator set at an altitude above 1000 feet calculate the altitude derating to determine maximum AC load capacity Models with Idlematic Move the Idlematic switch to ON to activate this feature it controls engine speed so the set will operate at idle speed with no load and full speed when a load is connected Leave the Idlematic Switch OFF if there will be many small interrupted loads or loads under 0 8 amperes TABLE 1 APPROXIMATE POWER USAGE OF COMMON APPLIANCES Appliance or Tool Approximate Running Wattage Battery Charger Bench Grinder 8 in Circular Saw 7 1 4 in Coffee Maker Drill 3 8 in Electric Water Pump Electric Broom Electric Drill Electric Stove Per Element Electric Water Heater Portable Heater Refrigerator Space Heater Sump Pump Television Trimmer 12 in heavy duty 350 1000
18. els so equipped flashes during cranking or running or if the en gine starts and shuts off stop the engine and check the oil level Add oil as recommended in the Maintenance section 5 Proceed to Adding Loads in this section Manual Start Models 1 Open the fuel valve see Figure 5 4 0 kW sets and below Check to be sure that the speed control lever is in the high speed H position Figure 6 2 Set the choke lever to the CLOSE position Fig ure 6 or Figure 7 If the engine is warm from previous operation do not close the choke On models equipped with Idlematic switch 3 5 kW and above position the switch to the OFF position before starting Let the engine warm up for three to five minutes before switching the Idlematic switch to ON if desired 4 Move the engine switch to the On position 5 With one hand on the generator set to steady it grip the recoil handle and pull out smoothly and quickly Repeat as necessary When the en gine starts gradually open the choke lever as the engine warms up Allow the engine to warm up for three to five minutes before apply ing a load If the oil watch lamp on models so equipped flashes during cranking or running or if the en gine starts and shuts off stop the engine and check the oil level Add oil as recommended in the Maintenance section FUEL VALVE LOCATED AT REAR SERVICE SIDE OF GENSET UNDER LEFT END OF FUEL TANK
19. ensation in the engine and difficult starting Moisture accumulates because the en gine does not run often enough to reach normal op erating temperature This moisture can cause damage to the engine To prevent moisture damage run the generator set at 50 percent capacity electrical load see Specifi cations section two hours every four weeks A long exercise period is more effective than several short periods ENGINE BREAK IN Correct engine break in provides the ideal fitting of all internal moving metal parts which is essential for top engine performance For controlled engine break in 1 Operate the equipment as it is intended to be operated However for the first 1 1 2 hours if possible operate the equipment at half the available engine power occasionally operating at full power for brief periods Avoid prolonged low speed low power operation during break in 2 Proper engine oil is especially critical during break in because of the higher engine temper atures that can be expected See REC OMMENDED ENGINE OIL in Introduction Change the oil if it is not right for the tempera tures during the break in period See Table 3 3 Check the oil level twice day or after every 4 hours of operation during the first 24 hours of operation 4 Change the oil and oil filter 5 0 KW 6 0 kW gen sets after the first 24 hours of operation and have the valves readjusted by qualified tech nician OUT OF SERVICE PROTE
20. gases combustibles or explosive materials Generator sets present the hazard of electrical shock that can result in severe per sonal injury or death Never expose the genera tor set to rain snow or similar wet conditions when operating The muffler becomes very hot dur ing and after generator set operation and can cause severe burns Do not touch hot muffler The voltage surge at start up can damage appliances TV sets microwave ovens computers etc Always disconnect all loads before starting the generator set Electric Start Models 1 Open the fuel valve Figure 5 4 0 kW sets and below Be sure that the speed control lever is in the high speed H position Figure 6 2 Set the choke lever to the CLOSE position Fig ure 6 or Figure 7 If engine is warm from pre vious operation do not close the choke 3 On models equipped with Idlematic switch 3 5 kW and above position the switch to the OFF position before starting Let the engine warm up for three to five minutes before switching the Idlematic switch to ON if desired 4 Start the engine by pressing the Start On Stop switch to the START position Release switch when engine starts and it will return to the On position Gradually open the choke lever as the engine warms up Let the engine warm up for three to five minutes before applying load The voltmeter on the control panel will indicate generator output voltage If the oil watch lamp on mod
21. generator set cool down before proceeding 2 Remove the fuel line from the fuel shutoff valve and collect the fuel in a suitable container 3 See Figure 13 Unscrew the sediment bowl from the fuel supply valve and clean it 4 Remove the screen and clean any dirt and par ticulate off the screen 5 Reinstall the screen and sediment bowl At tach the fuel line securely to the fuel shutoff valve 5 0 And 6 0 kW Gensets These sets have a fuel filter screen mounted inside the gas tank at the fuel shutoff elbow The screen should be replaced when performance problems occur or bad fuel is suspected Have an Onan Ser vice Center perform this maintenance CARBURETOR FILTER ELEMENT zr m s EN 9 Wed d GASKET FIGURE 13 FUEL FILTER REPLACEMENT GENSETS 4 0 KW AND BELOW SPARK PLUG MAINTENANCE AND REPLACEMENT A spark plug with heavy combustion deposits can cause the generator set to misfire operate errati cally or stop running when a load is applied Re move the spark plug and clean carbon and other de posits off with a wire brush then inspect and mea sure plug gap Plug gap measurements are listed in the Specifications section If a plug is discolored or badly fouled replace it If necessary the fuel tank can be raised for easier service access as follows Fuel presents the hazard of fire or explosion that can cause severe personal injury or death Shut fuel valve and handle fuel tank carefully
22. he generator set frame Earth Ground Lug Terminal Ground the generator set to earth ground by con necting a suitable ground wire to the earth ground lug terminal on the generator set control panel then connect the other end of the wire to a suitable earth ground according to local electrical codes and con ditions Do not connect grounds from appliance loads to the Earth Ground Lug terminal Earth Ground Lug Ter minal is for connecting the generator set to earth ground only LOW OIL SHUTDOWN SYSTEMS 4 0 kW and below The Oil Watch light flashes during cranking if the oil level is low It also flashes and stops the generator set if the set is running and the oil level reaches the 11 low working level of the Oil Watch See Figure 8 Add oil as recommended in the Maintenance sec tion before attempting to restart UPPER OIL LIMIT OIL WATCH WORKING FIGURE 8 TYPICAL OIL WATCH GENSETS 4 0 KW AND BELOW 5 0 kW and above These gensets are equipped with pressure lubri cated engines that will automatically stop if low oil pressure is sensed A short time delay allows the engine to be started after an oil change If the en gine stops during running or starts but then stops check the oil level and add oil if needed as de scribed in the Maintenance section of this manual STOPPING 1 Remove all loads from the generator set 2 Let the generator set run for three to five min utes to allow the engine to c
23. he generator set is running use extreme caution around hot manifolds and moving parts etc ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH Disconnect starting battery before removing protective shields or touching electrical equipment Use rubber insu lative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment Do not wear damp clothing particularly wet shoes or al low skin surface to be damp when handling electrical equipment Use extreme caution when working on electrical compo nents High voltages can cause injury or death DO NOT tamper with interlocks Follow all applicable state and local electrical codes Have all electrical installations performed by a qualified licensed electrician Tag open switches to avoid accidental closure DO NOT CONNECT GENERATOR SET DIRECTLY TO ANY BUILDING ELECTRICAL SYSTEM Hazardous volt ages can flow from the generator set into the utility line This creates a potential for electrocution or property dam age Connect only through an approved device and after building main switch is open Consult an electrician in re gard to emergency power use GENERAL SAFETY PRECAUTIONS Have a fire extinguisher nearby Maintain extinguisher properly and become familiar with its use Extinguishers rated ABC by the NFPA are appropriate for all applica tions Consult the local fire department for the correct type of extinguisher fo
24. il drain plug and wear protective clothing Electric start models only Disconnect the cables from the starting battery negative cable first to reduce the risk of arcing Store battery in a cool dry place and connect to a charger every 30 days to maintain full charge Battery electrolyte can cause severe eye damage and burns to the skin Wear goggles rubber gloves and a protec tive apron when working with batteries Batteries present the hazard of explosion which can result in severe per sonal injury Do not smoke or allow any spark flame pilot light arc producing equipment or other ignition sources around the battery area Cover the generator set and store in a dry pro tected area Returning the Generator Set to Operation 1 2 3 Perform an inspection of the generator set Check tag on set to verify that oil viscosity is still correct for existing ambient temperature Electric start models only Clean and check battery Measure specific gravity 1 260 at 80 F 27 C and verify level to be at split ring If specific gravity is low charge until correct value is obtained If level is low add distilled wa ter and charge until specific gravity is correct DO NOT OVERCHARGE Battery electrolyte can cause severe eye damage and burns to the skin Wear goggles rubber gloves and a protec tive apron when working with batteries 5 14 Batteries present the hazard of explosion which can re
25. ion under OUT OF SERVICE PROTEC TION in this section Moving parts can cause severe per sonal injury or death Hot exhaust parts can cause severe burns Stay clear of hot or moving parts Make sure all protective shields and guards are secure in place before starting up the equipment CONTROL PANEL Figure 3 illustrates one of the control panels Differ ent sets use different receptacle panels see Figure 4 for illustration of a control panel on a 50 Hz set Components On Stop Switch Recoil only Start Models Al lows the engine to be started and run when the switch is in the On position Stops the engine when held in the Stop position Start On Stop Switch Electric Start Models Pushing switch into the Start position begins engine cranking When engine starts release the switch and it will return to the On position To stop the en gine hold the switch in the Stop position until the engine stops running NOTE The engine can be recoil started when the switch is in the On position Low Oil Light 4 0 kW and below Indicates low engine oil level Low Oil Light will flash during cranking or will flash during operation and the gen erator set will stop if the engine oil level is below the low working level Voltmeter Shows generator AC output voltage AC and DC Circuit Breakers Provide protection for the generator from short circuits or overloads Full Power Switch Allows operator to select full power operatio
26. issions are pro hibited Unauthorized modification removal or re placement of the engine label is prohibited You should carefully review Operator s and other manuals and information you receive with your gen set If you are unsure that the installation use maintenance or service of your genset is autho rized you should seek assistance from an ap proved Onan engine dealer or an approved dealer for your equipment California engine users may use the information be low as an aid in locating information related to the California Air Resources Board requirements for emissions control EMISSIONS CONTROL INFORMATION The California emissions control warranty statement is located Engine Warranty Information in the same packet of information as this manual when the en gine is shipped from the factory Engine Valve Lash Engine Ignition Timing Engine Fuel Requirements Engine Lubricating Oil Requirements Engine Fuel Mixture Settings Engine Adjustments Engine Emission Control System 28 See Specifications See Specifications The engine is certified to operate on unleaded gasoline See Fuel Recommendations in ntroduction See Engine Oil Recommendations in ntroduction These engines have precision manufactured carburetors which are not adjustable See Starting and Running the Set The engine emission control system consists of internal engine modifications Onon Cummins Power Generation 1400 73r
27. lass SG or SH oil also SG CD SG CE SH CD or SH CE hav ing an SAE viscosity grade appropriate for the expected temperatures as indicated by Table 3 DO NOT FILL TO A LEVEL ABOVE THE FULL MARK ON THE DIPSTICK Drain the excess oil if too much has been added Too much oil can cause high oil consumption high operating temperatures and oil foaming Too little oil can cause se vere engine damage Keep the oil level be tween the Full and Add marks on the dip stick Reinstall the dipstick and cap after checking or adding oil making sure the cap is properly seated On engines with long oil fill tubes se cure the cap by pushing it down and turning it clockwise OIL AND FILTER CHANGE NOTE Sets 4 kW and below do not use oil filters State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Do not contact or ingest Use rubber gloves and wash exposed skin See Table 2 for scheduled oil change and filter re placement See Figures 9 and 10 for oil filter and oil drain locations 1 Run the engine until it is warm Stop the engine and disconnect the spark plug and if so equipped the battery negative cable Make sure the set is level Accidental starting of the en gine can result in severe personal injury or death Always disconnect the spark plug and the battery negative cable before changing oil 2 Remove the oil fill cap Crankcase pressu
28. n from the 120 VAC receptacles or shared power between the 120 VAC and 240 VAC receptacles Switch setting also affects voltmeter readings refer to voltmeter description Idlematic Switch 3 5 kW and above Automatic engine speed control In the On position the engine operates at idle speed until a load is applied The Idlematic automatically increases the engine to full speed when a load is applied This feature reduces engine wear and conserves energy In the Off posi tion the engine operates at full speed Earth Ground Lug Terminal Allows the generator set to be grounded to earth ground Additional Controls ator set is not in use See Figure 5 Fuel Valve Controls fuel flow to engine Setting fuel valve to Open position allows fuel to flow to en Choke Lever Restricts air flow to the carburetor gine Set fuel valve to Closed position when gener for starting a cold engine See Figure 6 or Figure 7 AC BREAKER START ON STOP DC BREAKER AC VOLTMETER RESET SWITCHES SWITCH RESET SWITCH DC Breaker 120 120 240V DC AC Breakers e e e Start Idlematic DC RECEPTACLE PLUG IDLEMATIC WITH JUMPER CLIPS EARTH SWITCH INCLUDED WITH GENSET GROUND OPTIONAL LUG AC RECEPTACLES 120 VAC AC RECEPTACLE 120 240 VAC On 12V 10A s D 120 240 Stop A e e e 15 GNI 30A 30A FACEPLATE WITH AC RECEPTACLES 60 HZ GENSETS ES1961 1 FACEPLATE WITH
29. nut 1 1 2 turns after seating it on the cover Reinstall the foam wrapper and outer cover PAPER amp FOAM M1845 1 MOUNTING TABS DO NOT TWIST FIGURE 11 AIR FILTER REPLACEMENT GENSETS 4 0 KW AND BELOW QUARTER TURN FASTENER MOUNTING NUT AIR CLEANER ASSEMBLY BABET C FOAM WRAPPER AIR CLEANER ELEMENT COVER FIGURE 12 AIR FILTER REPLACEMENT 5 0 KW AND 6 0 KW GENSETS 19 BATTERY CARE To increase battery life perform these routine checks and preventive measures Accidental starting of the gen erator set during maintenance can cause severe personal injury or death Discon nect both generator set starting battery cables before performing maintenance Remove the negative cable first to re duce the risk of arcing Ignition of explosive battery gases can cause severe personal injury Do not smoke or allow any flame spark pilot light arc producing equipment or other ignition sources near the battery Battery electrolyte can cause severe eye damage and skin burns Wear goggles rubber gloves and a protective apron when working with batteries 1 Keep the battery case clean and dry Wipe bat tery case with a damp cloth whenever dirt ac cumulates 2 Make certain that the battery cable connec tions are clean and tight To remove the battery cables use a battery puller tool 3 Identify the cable as positive or negative before making the connection Always
30. ool down 3 Close the fuel valve Gasoline presents the hazard of fire or explosion that can result in severe personal injury or death Always close the fuel valve when the engine is not in use to reduce the risk of fuel leakage 4 Stop the generator set by pressing and holding the Start On Stop or On Stop switch in the OFF position until the generator set comes to a complete stop 12 OPERATING RECOMMENDATIONS High Low Operating Temperatures High Operating Temperatures 1 See that nothing obstructs the airflow to and from the generator set 2 Keep the engine cooling fins clean Air hous ings should be properly installed and main tained 3 Use the proper viscosity oil as recommended in the oil change description Low Operating Temperatures 1 Use fresh gasoline and keep the tank filled to avoid condensation 2 Keep the spark plug clean and correctly gapped 3 Use the proper viscosity oil as recommended in the oil change description Extremely Dusty or Dirty Conditions Observe the following procedures when operating the generator set in extremely dusty or dirty condi tions 1 Keep the generator set clean and do not allow dust and dirt to accumulate 2 Clean the air cleaner more often than shown in the maintenance schedule 3 Keep oil and gas in dust tight containers suit able for storage of fuels Generator Set Exercise Infrequent operation of the generator set can result in moisture cond
31. pilled oil and fuel from the generator set immediately with a dry rag Dispose of cleaning rag properly Do not allow dirt to accumulate on the en gine cooling fins or on the control components and electrical connections A damp cloth can be used to clean dust and dirt from the generator set Cleaning solvents should not be used because they can damage electrical connectors and components Troubleshooting The following troubleshooting guide can be used for basic problem diagnosis If these recommendations do not resolve the problem contact an authorized Onan service center Many troubleshooting procedures present hazards which can result in severe person al injury or death Only qualified service personnel with knowledge of fuels electricity and ma chinery hazards should perform service procedures Review safety precautions on inside cover page FAILS TO CRANK ELECTRIC START MODELS CRANKS SLOWLY ELECTRIC START MODELS ENGINE WON T START EXHAUSTING BLACK SMOKE UNIT RUNS THEN STOPS UNIT RUNS THEN SURGES NO AC OUTPUT VOLTAGE NO DC OUTPUT VOLTAGE hot generator set can cause severe burns Always allow the generator set to cool 1 Low battery Bad battery connection Low battery Bad battery connection Oil is too heavy Load is connected Fuel below genset pickup level in tank Fuel supply shutoff valve closed Carbon deposits on spark plug Low oil level Choke stuck Dirty ai
32. r filter Rich fuel mixture Out of fuel Low oil level Excess oil Loose or worn spark plug lead Faulty spark plug Dirty fuel filter or generator set at too steep of an angle Governor out of adjustment or lean fuel mixture Open AG circuit breaker due to an overload Open DC circuit breaker due to an overload before performing any maintenance or service 24 Check battery electrolyte level 2 Clean and tighten all battery and cable connections Check battery electrolyte level Clean and tighten all battery and cable connections Replace with recommended oil Disconnect load while starting Add fuel Fully open fuel supply valve Remove spark plug and clean Add oil if necessary Open choke Clean or replace air filter Contact an Onan service center Add fuel Add oil Reduce engine oil level Check spark plug lead connection Remove and clean or replace Check fuel filter and angle of generator set Contact an Onan service center Remove all loads reset breaker check loads for defects Do not exceed rated load specifications Remove all loads reset breaker check for shorted battery or load defects Do not exceed rated load specifications Specifications B HZGENSETS 25EGHAA 40EGHAB 4 0 EGHEB Non CSA Certified ACOUIPUE Frequency Hera amp 4000 3500 292746 DC OUTPUT 12 VDC 120
33. r various applications Benzene and lead found in some gasoline have been identified by some state and federal agencies as causing cancer or reproductive toxicity When checking draining or adding gasoline take care not to ingest breathe the fumes or contact gasoline Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxic ity When checking or changing engine oil take care not to ingest breathe the fumes or contact used oil Remove all unnecessary grease and oil from the unit Ac cumulated grease and oil can cause over heating and en gine damage and present a potential fire hazard DO NOT store anything on the generator set such as oil cans oily rags chains wooden blocks etc A fire could result or operation could be adversely affected Keep the generator set clean and dry at all times Do not work on this equipment when mentally or physically fatigued or after consuming any alcohol or drug that makes the operation of equipment unsafe KP 7 Table of Contents Title Page Safety PIEGAUNONS 5 sos ardet drones an aie os his ant Anne Inside Front Cover IDITOGUGHOLI 4 nese Ree cies C Se 2 Starting and R nning the Set uos ne tree TAG Fe LET 5 Maintenance Pr 15 Troubleshooting eoa seede MS MSN 24 Specificallons RL LR er ek 25 Important Information for California Genset Users
34. re can blow hot engine oil out the fill opening causing severe burns Always stop the genset be fore removing the oil fill cap 3 Place a pan under the oil drain opening and re move the oil drain plug Reinstall the plug se curely after the oil has drained completely Gensets 5 0 and above Spin off the oil filter canister drain the oil and discard the filter ac cording to local regulations Thoroughly wipe off the filter mounting surface Make sure the gasket is in place on the filter canister and apply a thin film of oil to the gasket Spin on the new filter canister by hand until the gasket just touches the mounting pad and then turn it an additional 1 2 to 3 4 turn Do not over tighten Refill with API Class SG or SH oil also SG CD SG CE SH CD or SH CE having an SAE vis cosity grade appropriate for the expected tem peratures as indicated by Table 3 See Speci fications for the oil capacity TABLE 3 OIL VISCOSITY VS TEMPERATURE SAE VISCOSITY a EXPECTED AMBIENT TEMPERATURES 32 F 0 C and higher 40 OnaMax 10W 30 10W 40 20 F to 50 F 28 C to 10 C 5W 30 10 F to 100 F 12 C to 38 C 0 F to 80 F 18 C to 27 C OIL DRAIN PLUG DO NOT FILL TO A LEVEL ABOVE THE FULL MARK ON THE DIPSTICK Drain the excess oil if too much has been added Too much oil can cause high oil consumption high operating temperatures and oil foaming Too little oil c
35. sixth cleaning or sooner if dusty conditions exist or if the paper is torn 3 Reassemble filter into the housing and careful ly install the air cleaner cover 5 0 And 6 0 kW Gensets 1 18 Remove the outer cover by rotating the quar ter turn fastener counterclockwise to its verti cal position Then lift the cover and remove it See Figure 12 2 Foam wrapper only When cleaning the foam wrapper do not remove the inner air cleaner cover Remove and wash the foam wrapper in water and detergent Squeeze the foam wrapper dry like a sponge Rinse with clean water and allow it to dry Coat the wrap per evenly with one tablespoon 14 grams of SAE 30 engine oil Knead the oil into the wrap per and wring out the excess oil Failure to adequately wring out excess oil from the wrapper may cause a drop in engine power due to a restriction of inlet air 3 Re install the foam wrapper over the paper air cleaner element by stretching it over the inner cover Completely cover all exposed paper pleats Replace the foam wrapper when it be comes torn or stretched 4 Air cleaner element replacement To keep debris out of the engine move the choke lever to the full choke position to close the choke plate Remove the mounting nut inner cover and air cleaner element Wipe off dust and de bris from the air cleaner base Install the new paper element and secure it with the inner cover and mounting nut Tighten the
36. sult in severe per sonal injury Do not smoke or allow any spark flame pilot light arc producing equipment or other ignition sources around the battery area Check the condition of the air filter and check the engine oil level Open the fuel supply valve 6 Start the generator set Initial start up may be slow due to oil in the cylinder Smoke and rough operation will occur until the oil in the cyl inder is exhausted If the engine does not start check the spark plug Apply 50 percent load to the generator set until it runs smoothly Run the generator set for an hour Remove the load and let the generator set run for three to five minutes to cool down The gen erator set is now ready for operation Maintenance Periodic maintenance is essential for top perfor mance Use Table 2 as a guide Under hot or dusty operating conditions some maintenance opera tions should be performed more frequently as indi cated 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 Accidental starting of the generator set during maintenance can cause severe per sonal injury or death Before performing main tenance disconnect the spark plug wire from the spark plug Electric start models discon nect both generator set starting battery cables Remove the negative cable first to red
37. t gases to the outside well away from all windows doors vents and other openings into the building or enclosure It is the responsibility of the equipment operator s to check for exhaust leaks on a daily basis and to have all leaks repaired before continuing to operate the equipment Starting and Running the Set AWARNING EXHAUST GAS IS DEADLY Exhaust gases contain carbon monoxide an odorless and colorless gas Carbon monoxide is poi sonous and can cause unconsciousness and death Symptoms of carbon monoxide poisoning in clude Dizziness Nausea e e e Headache e Weakness and Sleepiness Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS GET OUT INTO THE FRESH AIR IMMEDIATELY If symptoms persist seek medical attention Shut down the engine and do not operate it until it has been inspected and repaired Make certain the exhaust system is properly installed Inspect it every time the engine is started and after every eight hours of continuous operation PRE START CHECKS Before the first start of the day and after every eight hours of operation perform the maintenance listed in Table 2 Periodic Maintenance Schedule of this manual Keep a log of maintenance and the hours run and perform any maintenance that may be due If the set has been in storage return the engine to service as instructed in Returning The Genset To Operat
38. to prevent fuel leakage Reduce fuel level in fuel tank to reduce the risk of spilling fuel Do not permit any flame spark pilot light cigarette arcing switch or equipment or other ignition source near the fuel system Keep an ABC type fire extinguisher nearby 1 Let the generator set cool down before servic ing Check fuel level in the fuel tank and reduce the level if tank is full to avoid spilling Use a pump designed for use with fuels to lower fuel tank level and store fuel in a clean container de signed for fuel storage 2 Close the fuel shutoff valve on the bottom of the fuel tank Figure 5 3 Remove the fuel tank mounting nuts and raise the control panel side of the fuel tank high enough to access the spark plug Support the fuel tank to prevent tilting or dropping e Black deposits indicate a rich mixture e A wet plug indicates misfiring e Badly or frequently fouled plug indicates the need for a major tune up Refer to Table 2 for scheduled spark plug inspection and replacement and to Specifications for gap size To prevent crossthreading the spark plug always thread it in by hand until it seats If the spark plug is being reused turn it with a wrench an additional 1 4 turn If the spark plug is new turn it an additional 3 8 to 1 2 turn If you have a torque wrench tighten the spark plug to 20 Ibs ft 26 Nem MUFFLER SERVICE A hot muffler can cause severe burns Allow the generator set to cool before
39. uce the risk of arcing AWARNING A hot generator set can cause se vere burns Always allow the generator set to cool before performing any maintenance or ser vice TABLE 2 PERIODIC MAINTENANCE SCHEDULE SERVICE INTERVAL SERVICE THESE ITEMS Change Engine Oil and Filter if so equipped Clean Air Cleaner Foam Wrapper iil oie Son HOURS MONTH HOURS HOURS i Clean Cylinder Cooling Fins SS _ Check Starting Battery if equipped 24 Clean Spark Plug SE Clean and Inspect Muffler O a a Replace Fuel Filter E Aa _ Inspect Clean and Regap Spark Pug pf x Replace Spark Plug Adjust Valve Lash Clearance 064 Clean Carburetor and Fuel Tank em EEE Replace Air Cleaner Element Fe ME HE 1 Check for loose parts and for oil and fuel leaks Check exhaust system audibly and visually with the generator set running Repair any leaks immediately Replace corroded exhaust and fuel line components before leaks occur 2 Perform after first 24 hours of operation on new sets 3 Perform more often in extremely dusty conditions 4 Perform more often when operating in hot conditions 5 instructions for battery care provided by the equipment or battery manufacturer 6 Must be performed by a qualified mechanic equipment or Onan dealer 15 DAILY 8 HOUR MAINTENANCE The operator should check the following before the first start of the day and after every
40. uel Tank Capacity Rated Output Operating Hours Battery Requirements Battery Group U1 Cold Cranking Amps at 32 F 09 C 50 110 220 2000 1800 16 4 8 2 12 VDC 100 W 8 3 A GH170 3000 Gasoline 0 63 qt 0 6 L 0 028 in 0 7 mm Intake and Exhaust 0 002 0 0039 in 0 05 0 10 mm 21 Recoil 5 5 bhp max 169 119 Ib 54 kg 26 8 681 22 559 24 6 625 6 5 gal 24 6 L 20 5 50 110 220 3500 3000 27 2 13 6 12 VDC 100 W 8 3 A GH280 3000 Gasoline 0 95 qt 0 9 L 0 028 in 0 7 mm Intake and Exhaust 0 002 0 0039 in 0 05 0 10 mm 25 Electric Recoil 9 0 bhp max 274 165 Ib 75 kg 26 8 681 22 559 24 6 625 6 5 gal 24 6 L 13 5 12 volt 235 50 110 220 5000 4500 40 9 20 4 12 VDC 100 W 8 3 A Elite E140H 3000 Gasoline 1 0 qt 0 95 L 0 035 in 0 89 mm Intake and Exhaust 006 010 in 0 15 0 25 mm 23 Electric Recoil 14 bhp max 390 207 Ib 94 kg 29 2 742 22 5 572 28 719 8 0 gal 30 3 L 10 5 12 Volt 235 Important Information for California Users The Pro series Portable Gensets meets the require ments of California s Exhaust Emissions Standards for 1995 and later for Utility and Lawn and Garden Equipment Engines As a California user of this engine please be aware that unauthorized modifications or replacement of fuel exhaust air intake or speed control system components that affect engine em
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