Oran PRO Eghem, PRO Egheb, PRO Egham, PRO Eghab, PRO Eghaa User Manual
Operator’s Manual
Models
EGHAM, EGHEM, EGHAA, EGHAB, EGHEB
Portable Generator Sets (Pro Series)
965-0100Printed in U.S.A. 10-95
Safety Precautions
Redistribution or publication of this document,
by any means, is strictly prohibited.
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 equipment is properly operated and maintained. Many accidents
are caused by failure to follow fundamental rules and precautions.
The following symbols, found throughout this manual, alert you
to potentially dangerous conditions to the operator, service personnel, or the equipment.
This symbol warns of immediate hazards which will result in severe personal injury or
death.
This symbol refers to a hazard or unsafe
practice which can result in severe personal injury or
death.
This symbol refers to a hazard or unsafe
practice which can result in personal injury or product or property damage.
Fuels, electrical equipment, batteries, exhaust gases and moving 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 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 ignited by electrical arcing or by smoking.
EXHAUST GASES ARE DEADLY
•
Engine exhaust contains CARBON MONOXIDE, a dangerous gas that is potentially lethal. Avoid carbon monoxide 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 exhaust 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 accidental 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.
• If adjustments must be made while the 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 insulative 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 allow 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 applications. Consult the local fire department for the correct type
of extinguisher for 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 toxicity. 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 engine 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
Redistribution or publication of this document,
by any means, is strictly prohibited.
Title Page
Safety Precautions Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting and Running the Set 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Important Information for California Genset Users 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARNING
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.
!!
The engine exhaust from this product
contains chemicals known to the State
of California to cause cancer, birth
defects or other reproductive harm.
1
Introduction
Redistribution or publication of this document,
by any means, is strictly prohibited.
This manual describes the Onan Pro series portable generator sets. Study this manual and comply
with all warnings and cautions. Using and maintaining the set correctly will result in longer set life, better performance, and safer operation.
The Onan warranty form (generator and control
only) comes with the set manual. A service manual
WRITE MODEL AND SERIAL NUMBERS HERE
may be ordered through an Onan dealer or distributor.
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.
MODEL NUMBER:
SERIAL NUMBER:
SET NAMEPLATE LOCATED ON
OPPOSITE SIDE OF GENERATOR
SERIAL NUMBER PLATE
FIGURE 1. GENSET IDENTIFICATION
2
RECOIL
Redistribution or publication of this document,
by any means, is strictly prohibited.
STARTER
ELECTRIC STARTER
LOCATION (OPTIONAL)
2.0 KW, 2.5 KW, 3.5 KW, 4.0 KW GENERATOR SETS
FUEL FILL
RECEPTACLE/
CONTROL
PANEL
BATTERY TRAY LOCATION
(SETS WITH ELECTRIC START)
OIL FILL &
DIPSTICK
RECOIL
STARTER
ELECTRIC
STARTER
FUEL FILL
OIL FILL &
DIPSTICK
5.0 KW, 6.0 KW GENERATOR SETS
RECEPTACLE/
CONTROL
PANEL
BATTERY
TRAY
FIGURE 2. COMPONENT LOCATIONS
3
FUEL RECOMMENDATIONS
Redistribution or publication of this document,
by any means, is strictly prohibited.
Use clean, fresh unleaded gasoline with an octane
rating (anti-knock index) of 87 or higher.
During some times of the year only mandated “oxygenated” gasolines may be available; these are acceptable for use, but not preferable. Using leaded
gasoline will result in the extra maintenance required for removing combustion chamber and
spark plug deposits. Do not use gasoline or gasoline additives (de-icers) containing methanol, which
can be corrosive to fuel system components.
Single-grade SAE 30 oil is better when temperatures 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 starting battery. Prompt starting requires sufficient battery capacity and battery cable size. Neither cranking performance nor starter service life will be adequate with an undersized battery.
CAUTION
Do not use gasoline or gasoline additives containing methanol because methanol
can be corrosive to fuel system components.
Avoid using highly leaded gasolines and lead
additives because of the extra engine maintenance that will be required.
WARNING
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 equipment. Keep flames, sparks, pilot lights, electrical arcs and arc-producing equipment and all
other sources of ignition well away.
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 Automotive Engineers) viscosity grade. See the Oil
Change description for the viscosity grade appropriate for the temperatures expected.
See
Maintenance
and any instructions available
from the battery manufacturer for battery maintenance. Note that as long as the set is run regularly ,
the automatic battery recharging system on the engine should maintain battery charge. See OUT -OFSERVICE PROTECTION under
ning the Set
regarding battery care during storage
Starting and Run-
for prolonged periods.
EXHAUST SYSTEM
EXHAUST GAS IS DEADLY! Generator sets must
never be operated inside buildings or other enclosed 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 exhaust 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.
4
Starting and Running the Set
Redistribution or publication of this document,
by any means, is strictly prohibited.
EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
•
Dizziness
•
Nausea
•
Headache
•
Weakness and Sleepiness
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.
•
Throbbing in Temples
•
Muscular Twitching
•
Vomiting
•
Inability to Think Coherently
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
Operation
TION in this section.
WARNING
under OUT-OF-SERVICE PROTEC-
Moving parts can cause severe per-
Returning The Genset To
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. Different 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):
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.
Al-
cranking. When engine starts, release the switch
and it will return to the On position. To stop the engine, 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):
engine oil level. Low Oil Light will flash during
cranking or will flash during operation and the generator 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:
for the generator from short circuits or overloads.
Full Power Switch:
power operation 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.
Allows operator to select full
Idlematic Switch (3.5 kW and above):
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 position the engine operates at full speed.
Indicates low
Provide protection
Automatic
Start/On/Stop Switch (Electric Start Models):
Pushing switch into the Start position begins engine
Earth Ground Lug T erminal:
set to be grounded to earth ground.
Allows the generator
5
Additional Controls
Redistribution or publication of this document,
by any means, is strictly prohibited.
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 engine. Set fuel valve to Closed position when gener-
START/ON/STOP
SWITCH
DC BREAKER
RESET SWITCH
AC VOLTMETER
Choke Lever:
Restricts air flow to the carburetor
for starting a cold engine. See Figure 6 or Figure 7.
AC BREAKER
RESET SWITCHES
FULL POWER
SWITCH
IDLEMATIC
SWITCH
(OPTIONAL)
DC RECEPTACLE (PLUG
WITH JUMPER CLIPS
INCLUDED WITH GENSET)
EARTH
GROUND
LUG
AC RECEPTACLES
(120 VAC)
AC RECEPTACLE
FACEPLATE WITH AC RECEPTACLES (60 HZ GENSETS)
FACEPLATE WITH COVERED AC RECEPTACLES (50 HZ GENSETS)
FIGURE 3. CONTROL PANEL
(120/240 VAC)
ES1961-1
6
E
Redistribution or publication of this document,
by any means, is strictly prohibited.
(GROUND
SOCKET)
N
(NETRAL
SOCKET)
N
(120 VAC TO
GROUND)
UK RESIDENTIAL
RECEPTACLE
(GREY − 13 AMP, 220/240V)
N
(120 VAC TO
GROUND)
E
(GROUND
SOCKET)
EUROPEAN INDUSTRIAL RECEPTACLE
(BLUE − 16 AMP, 220/240V)
L
(120 VAC TO
GROUND)
L
(120 VAC TO
GROUND)
L
(120 VAC TO
GROUND)
UK INDUSTRIAL RECEPTACLE
(YELLOW − 16 AMP, 110/130V)
GROUND
CONNECTION
L
(120 VAC TO
GROUND)
GROUND
CONNECTION
GERMAN RESIDENTIAL RECEPTACLE
E
(GROUND
SOCKET)
N
(120 VAC TO
GROUND)
(GREY − 16 AMP, 220V)
E
(GROUND
PIN)
L
(120 VAC TO
GROUND)
FRENCH RESIDENTIAL
RECEPTACLE
(GREY − 16 AMP, 220V)
N
(120 VAC TO
GROUND)
FIGURE 4. RECEPTACLE VARIATIONS, 50 HZ GENERATOR SETS
7
STARTING PROCEDURE
Redistribution or publication of this document,
by any means, is strictly prohibited.
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 sequence.
WARNING
Inhalation of exhaust gas can result
in severe personal injury or death. Do not operate 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.
WARNING
Due to the danger of severe personal injury or death, do not operate the generator
set in hazardous areas where it might ignite
gases, combustibles, or explosive materials.
WARNING
Generator sets present the hazard
of electrical shock that can result in severe personal injury or death. Never expose the generator set to rain, snow, or similar wet conditions
when operating.
WARNING
The muffler becomes very hot during and after generator set operation and can
cause severe burns. Do not touch hot muffler.
CAUTION
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 (Figure 6 or Figure 7). If engine is warm from previous 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 models so equipped)
flashes during cranking or running, or if the engine 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 (Figure 6 or Figure 7). If the engine is warm from
previous 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. 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 engine starts, gradually open the choke lever as
the engine warms up. Allow the engine to
warm up for three to five minutes before applying a load.
If the oil watch lamp (on models so equipped)
flashes during cranking or running, or if the engine starts and shuts off, stop the engine and
check the oil level. Add oil as recommended in
the Maintenance section.
8
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