Page 1
Onon
Installation
Manual
OF
Diesel
960-0601
6-88
Printed in U.SA
Driven
Page 2
Safety Precautions
V,
Before operating the generator set, read the Operator's Manual and become familiar with it and the 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.
A
DANGER
personal injury or death.
AWARNING
severe personal injury or death.
ACAUTION
personal injury or product or property damage.
FUEL
AND
FUMES
can
result
from
• DO NOT fill fuel tanks while engine is running, unless
tanks are outside the engine compartment. Fuel contact
with hot engine or exhaust is a potential fire hazard.
• DO NOT permit any flame, cigarette, pilot light, spark, or
other ignition source near the generator set or fuel tank.
• Fuel lines must be adequately secured and free of leaks.
Fuel connection at the engine should be made with an
approved flexible line. Do not use copper piping on
ble lines as copper will become brittle if continuously
vibrated or repeatedly bent
• Be sure all fuel supplies have a positive shutoff valve.
• Do not smoke while servicing lead acid batteries. Lead
acid batteries emit a highly explosive hydrogen gas that
can be ignited by electrical arcing or by smoking.
EXHAUST
• Provide an adequate exhaust system to properly expel
• Be sure the°unit is well ventilated.
MOVING
OR
DEATH
• Keep your hands, clothing, and jewelry away from moving
• Before starting work on the generator set, disconnect
GASES
discharged
daily for leaks per the maintenance schedule. Ensure that
exhaust manifolds are secure and not
exhaust gases to heat a compartment.
PARTS
parts.
starting batteries, negative (-) cable first. This will prevent
accidental starting.
This symbol warns of immediate
hazards which will result in severe
This symbol refers to a hazard or
unsafe practice which can result in
This symbol refers to a hazard or
unsafe practice which can result in
ARE
FLAMMABLE.
improper
gases.
CAN
practices.
ARE
DEADLY
Visually and audibly inspectthe exhaust
CAUSE
SEVERE
Fire
and explosion
warped.
PERSONAL
Do not use
INJURY
flexi-
• Make sure that fasteners on the generator set are secure.
Tighten supports and clamps, keep guards in position
over fans, drive belts, etc.
• Do not wear loose clothing or jewelry in the vicinity of
moving parts, or while working on electrical equipment.
Loose clothing and jewelry can become caught in moving
parts.
Jewelry can short out electrical contacts and cause
shock or burning.
• If adjustment must be made while the unit is running, use
extreme caution around hot manifolds, moving parts, etc.
ELECTRICAL
INJURY
• Remove electric power 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 components.
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
tages can flow from the generator set into the utility line.
This creates a potential for electrocution or property
damage. Connect only through an approved isolation
switch or an approved paralleling device.
GENERAL
• Coolants under pressure have a higher boiling point than
water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator
set to cool and bleed the system pressure first.
• Provide appropriate fire extinguishers and install them in
conven ient locations. Consult the local fire department for
the correct type of exti nguisher to use. Do not use foam on
•> electrical fires. Use extinguishers rated ABC by NFPA.
• Make sure that rags are not left on or near the engine.
• Remove all unnecessary grease and oil from the unit.
Accumulated grease and oil can cause overheating and
engine damage which present a potential fire hazard.
• Keep the generator set and the surrounding area clean
and free from obstructions. Remove any debris from the
set and keep the floor clean and dry.
• Do not work on this equipment when mentally or physically
makes the operation of equipment unsafe.
SHOCK
OR
DEATH
High voltages can cause injury or death. DO NOT
SAFETY
fatigued,
CAN
CAUSE
PRECAUTIONS
or after consuming any alcohol or drug that
SEVERE
PERSONAL
vol-
LS-8
Page 3
Table of Contents
SAFETY PRECAUTIONS Inside Front Cover
INTRODUCTION 2
About this Manual 2
Installation Overview 2
SPECIFICATIONS
MOUNTING THE GENERATOR SET 5
General 5
Location 5
Mounting 5
Access to Set 5
MECHANICAL CONNECTIONS 6
Fuel System 6
Exhaust System 7
Ventilation System 8
Cooling System 8
ELECTRICAL CONNECTIONS 11
General • 11
Transfer Switch 11
AC Wiring 11
DC Wiring 14
PRESTART PREPARATIONS 16
Coolant 16
Lubrication 16
Fuel 17
Ventilation 17
Exhaust 17
Electrical 17
Mechanical -. 17
INITIAL START CHECKS 18
Starting 18
Engine Gauges 18
AC Meters (If Equipped) 18
Engine Monitor Indicator Lamps 18
Generator Voltage Checks 18
Generator Frequency 19
Exhaust System 21
Fuel System • 21
DC Electrical System 21
Cooling System 21
Mechanical Adjustments 21
3
Page 4
Introduction
ABOUT
This manual provides installation instructions for the OF
Series generator sets. This includes the following
information:
• Mounting — Recommendations for fastening generator set to base and space requirements for normal
operation and service.
• Mechanical Connections — Location of connection
points for
• Electrical Connections — Location of electrical
nection points for the control, generator, and starting
system.
• Prestart — Checklist of items or procedures needed
to prepare generator set for operation.
• Initial Startup — Test complete system lo ensure
proper installation, satisfactory performance, and
safe operation. iRefer to Qperators Manual for
bleshootingJ;nfor;mation.
This manual DOES NOT provide application informati o n fo r selecting agenerator set m design ing the com plete installation. If it is necessary to design the various
integrated systems (fuel, exhaust, cooling,
standard installation practices, or specify system materials,
additionahinformation
data specific tothe .generatorset, refer to ihe OF Series
specification and product data sheets. For generator
application information about ^generator set installation,
refer to the following Onan Technical Bulletins.
fuel,
. . .
THIS
exhaust, ventilation, and cooling.
MANUAL
isrequired.
trou-
etc.),
review
For engineerinjg
con-
Application and Installation
A standby power system must be carefully planned and
correctly installed to ensure proper operation. This
involvestwoessentialelements:applicationand installation.
•Application (as it applies to generator set installations)
refers to the design of the complete standby power
system that usually includes power distribution equipment, transfer switches, ventilation equipment, mounting pads, and cooling, exhaust, and fuel systems. Each
component must be correctly designed so the complete
system will function as
is an engineering function generally done by specifying
engineers .or other trained,specialists. Specifying
neers are responsible for the design of the complete
standby system and for selecting the materials and products required.
Installation refers to the actual set-up and assembly of
the standby power system. The installers set-up and
connectthe various components ofthe system as speci-
fied in the system design plan. The complexity of the
standby system normally requires the special skills of
qualified electricians, plumbers, sheetmetal workers,
etc. to complete the various segments of the installation.
This is necessary to ensure all components are
assembled using standard methods and practices.
ure 1 shows a typical instailation and Table 1 lists the
equipment installation specifications.
intended.
Application and design
engi-
Fig-
•
T-009/T-017 — Selecting Onan Generator Sets
T-030 — Installation Information for
Liq u id -Cooled GenSets
Bulletin T-030 is a particularly useful installation reference and is shipped with this manual. Bulletin
T-009/T-017 is included in the Onan Power Systems
Manual or may be obtained separately on request from
an authorized Onan distributoj'.
INSTALLATION
These installation recommendations apply to typical
generator set installations with standard model generator sets. Whenever possible, these recommendations
also cover factory designed options or modifications.
However, because of the many variables in any installation,
it is not possible to provide specific recommendations for every situation. If there are any ouestions not
answered by this manual, contact an Onan distributor
for assistance.
OVERVIEW
Safety
The generator set has beemcarefully designed to pro^
vide safe and efficient service. However, the overall
safety and reliability ofthe complete system is dependent on many factors outside the control of thegenerator
set manufacturer. To avoid possible safety hazards,
make all mechanical and electrical connections to the
generator set exactly as specified in this manual. All
systems external to the generator
cal,
certain all required inspections and tests have been
completed and all code requirements have been satisfied before certifying the installation is complete and
ready for service.
Considerations
(fuel,
exhaust, electri-
etc.) must comply with all applicable codes. Make
Page 5
Specifications
EQUIPMENT
Fuel System
Inlet Fitting Size
Return Fitting Size
Fuel Pump
(Lifting Capacity
Exhaust
System
Exhaust Connection
(in.
pipe thread)
Exhaust Backpressure
(Maximum Allowable)
Electrical System
Starting Voltage
Battery
INSTALLATION
SYSTEMS
TABLE
1.
SPECIFICATIONS
Two,
AWARNING
175
DFE
7/8-14
UNF-2A
3/4-16
djNF-2A
5feet(i:525 m)
5 inches NPT
41 inches H2O
3 inches Hg
24 Volts DC
12-Volt Group 8D
INCORRECT INSTALLATION, SERVICE OR REPLACEMENT OF PARTS CAN
RESULT IN
PERSONNEL MUST BE QUALIFIED
SEVERE
PERSONAL INJURY AND EQUIPMENT DAMAGE. SERVICE
TO
PERFORM ELECTRICAL AND MECHAN-
ICAL COMPONENT INSTALLATION.
Page 6
35*
THIMBLE
SWEEPING ELBOW
» DUCT
RGURE
1.
TYPICAL
DFE
INSTALLATION,
COOLING AIR INLET MUST BE
AT LEAST 1-1/2 TIMES LARGER
THAN RADIATOR DUCT OUTLET
AREA ON RADIATOR COOLED
MODELS.
FLOW OF COOLING AI R' AND
HEATED AIR MAY BE
TROLLED BY AUTOMATICALLY
OPERATED LOUVERS.
CON-
Page 7
Mounting
the Generator Set
GENERAL
Most generator set installations must be engineered to
ensure the generator set will function properly under the
expected load conditions. Use these instructions as a
general guide only. Follow the instructions of ^the
sulting engineer when locating or installing any;components.
The complete installation must comply with all
local and state building codes, fire ordinances, and
other applicable regulations. Refer to Onan Technical
Bulletin,
Requirements to be considered prior to installation:
• Level mounting surface
• Adequate cooling air
• Adequate fresh induction air
• Discharge of circulated air
• Discharge of exhaust gases
• Electrical connections
• Accessibility for operation and servicing
• Noise levels
• Vibration isolation
T-030, for further installation information.
con-
Use
3/4-inch
secure the generator set skid to the floor to prevent
movement. Secure the skid using a flat washer and
hexagon nut for each bolt (see Figure 2).
diameter, anchored mounting bolts to
HEX NUT
FLAT WASHER
•12
IN.
305 mm)
LOCATION
Generator set location is decided mainly by related systems such as ventilation, wiring,
set should be located as near as possible to the main
power fuse box.
Provide a location away from extreme ambient temperatures and protect the generator set from adverse
weather conditions. An optional housing is available for
outside operation.
fuel,
and exhaust. The
MOUNTING
Generator sets are mounted on a steel skid that provides
proper support. The engine-generator assembly is isolated from the skid frame by rubber mounts that provide
adequate vibration isolation for normal installations. For
critical installations, install vibration isolators between
the skid base and foundations.
Mount the generator set on a substantial and level base
such as a concrete
bolts and set mounting dimensions, see specific generator set specification sheet.
pad.
For proper spacing of mounting
MOUNTING
BOLT
FIGURE 2. BOLT DIAGRAM
ACCESS
Plan for access to the generator set for servicing and
provide adequate lighting around the unit. For convenience in general servicing such as the radiator, fan belt,
and changing the crankcase oil; the surface of the
mounting base should be at least 6 inches (152 mm)
above the floor.
TO SET
Page 8
Mechanical
Connections
The generator
includes connecting the
cooling systems. Before starting any type of
tion,
Onan recommends alii pertinent state and local
codes
be
inspected before the unit is put
Cummins engin es used on the
normally use ASTM No. 2 Diesel
set
mechanical: system instaUation
fuel,
exhaust, ventilation and
fuel
installa-
complied with and: the installation must
in,
FUEL
service.
SYSTEM
DF
series gen erator sets
fuel.
-
They
will,
how-
be
ever, operate orv dcesel fuels within the speeificattons
delineated
in
the.
Cummins engine manual.
General
In
all
fuel system tnstaiFattons, cfeantrness
utmost importance;. Make evety effort
trance *of moisture,, dirt
or
contaminants
is ot
to
prevent en-
of
any
the
kind.
Clean all fuel system components before installing.
Use only compatibfe.metaf tuet lines to avofdelectroly-
sis when fuel
ized
or
tends to flakeo.ff and eortfaminate the
section
lines;
must be buriedL Never use gafwart.-
copper
of
fuel;
tines or fittings wtth diesef fuel as
tubing; between, the engine and
fuel.
Useaflexibte
fuel:
it
supply
line to withstand.vibration.
ACAUTIOt*
fuel
systems.
Never use galvanized or copper fuel
lines,,
fittings oriuettanks wit ft diesel
Condensation in the tank and lines combines with the sulfur in diesel fuel to produce suffuric
acid. The molecufar structure of the copper or galvanized lines
or
tanks reacts with
the,
acid and contami-
nates the fuel.
A typical underground fuel system consists
of a
main
fuel tank, vent and fill pipes, fuel supply line, and fuel
return line (see Figure
1).
Ifthe tank is installed below the
lift capabilities ofthe standard fuel transfer pump, a day
tank and auxiliary pump will also
overhead tank is
be required
installed,
to
prevent fuel head pressures from being
a day tank and float valve will
be
required.
If
an*
placed on thefuel system components. Referto Technical Bulletin T-030 for examples
of
fuel supply systems
that require a day tank.
Day Tank
(If
Used)
Day tanks are fuel transfer tanks which aroused when
the standard engine fuel pump does not have the capac-
ity to draw the fuel
tank
is
overhead and presents problems
head pressure for the fuel return. See Figure
from:
the supply tank; or the supply
FUEL PUMP RETURN LINE
(jF USED);
INJECTOR,
FUEL RETURN-
LINE
Alii models require fueh return- line!
from injectors to tank.
FLOAT TYPE.SWITCH
CONNECT TO
AC OUTPUT ' " V
of
high fuel
3.
.fl-
VENT LINE
An electric solenoid shutoft vatve in the supply line
always desirabfe and! requtred! for indoor automatic, or
remote startmg instalfettors. Connect
'-wires
to
the battefy igpitioni ctreuit
the
sotenotd
to
open the valve
during generator set operation.
Supply
Tank
Locate the fuel tank as close as possible to the generator set and
fuel pump
within;
if
theSfoot
(1.5
metre} lift capacity ofthe
possiibfe. Choose a tank that has sufficient
capacity to keep thegenerator mnning. continuously at
full load for
AWARNING
personal
between engine andthe
and
leaks
applicable
at
least 36 hours.
Fuel
teaks
create
hazards
injury or death.
which can result
Always
fuel
supply
due to vibration. The
codes.
fire
and explosion
in
use
flexible
to avoid line failure
fuel
system
must
severe:
tubing
meet
is
'DAY' TANK
25 GAL. (20 LITRE)
MINIMUM CAPACITY
/
FUEL TRANSFER
PUMP - ELECTRIC
MOTOR DRIVEN
LARGER
OVERFLOW
FIGURE
UNE
3.
DAY TANK
SUPPLY/
LINE
ll
11
li
11
II
UNDERGROUND
11
It
11
1
FUEL
•
11
u
(TYPICAL)
TANK
FILL
PIPE
ES-1214-1
Page 9
Supply Tank Lower Than Engine: With this installation,
the day tank is installed near the generator set and
within the engine fuel pump lift capability, but below the
fuel injection system. Install an auxiliary fuel pump as
close as possible to the supply tank to pump fuel from
the supply tank to the day tank. A float switch in the day
tank controls operation of the auxiliary fuel pump.
The supply tank top must be below the day tank top to prevent
siphoning from the fuel supply tank to the day tank.
Provide a return line from the engine injection system
return connection to the day tank (near the
top).
Provide
a day tank overflow line to the supply tank in case the
float switch fails to shut off the fuel transfer pump.
AWARNING
Spilled fuel presents the hazard of
fire or explosion which can result in
severe personal injury or death. Provide an overflow
line to the
supply
tank from the day tank.
Supply Tank Higher Than Engine: Install the day tank
near the generator set and within the engine fuel pump
lift capability, but below the fuel injection system. Use
fuel line at least as large as the fuel pump inlet. The
engine fuel return line must-enter the day tank.
Include a shutoff solenoid in the fuel line between the
fuel supply tank and the day tank. It stops fuel flow when
the generator set is off.
RAIN CAP
HOLES IN END OF
INNER SLEEVE
ROOF
(230 mm) (230 mm)
9 INCH MIN , tt 9 INCH MIN
WALL OR PARTITION
Diameter ol Thimble Must Be 12 Inches (305 mm)
Larger Than Diameter of Exhaust Pipe
DRIP CAP
9 INCH MINIMUM
(230 mm).
9 INCH MINIMUM
(230 mm)
,1)1^/-
HOLES IN
V
END
INNER SLEEVE
OF
EXS-1036
Engine
Fuel
Connections
Identification tags are attached to the fuel supply line
and fuel return line connections by the factory. Flexible
lines for connecting between the engine and the stationary fuel line are supplied as standard equipment.
Refer to Table 1, SPECIFICATIONS tor the fitting sizes.
EXHAUST
SYSTEM
Pipe exhaust gases to the outside of any enclosure.
Locate the exhaust outlet away from air inlets to avoid
exhaust gases from re-entering the enclosure. Exhaust
installations are subject to various detrimental conditions such as extreme heat, infrequent operation, and
light loads. Regularly inspect the exhaust system both
visually and audibly to ensure the entire system remains
fume tight and safe for operation.
AWARNING
death. Use extreme care during installation
tight exhaust
Inhalation of exhaust gases can
result in severe personal injury or
to
ensure a
system.
Use an approved thimble (Figure 4) where exhaust
pipes pass through wall or partitions. Refer to the
National Fire Protection Association Bulletin, Volume 4,
section 211 covering Standards for Chimneys, Fireplaces and Vents for suggested code requirements. Build
according to the code requirements in effect at the
installation site.
FIGURE 4. EXHAUST THIMBLE (TYPICAL)
AWARNING
Inhalation of exhaust gases can
result in severe personal injury or
death. Do not use exhaust heat to warm a room, com-
partment, or storage area.
Onan has rain caps available for the discharge end of
vertical exhaust pipes. The rain cap clamps onto the end
of the pipe and opens due to exhaust discharge force
from the generator set. When the generator set is
stopped,
the exhaust system from
ACAUTION
Support
the rain cap automatically closes, protecting
rain,
snow, etc.
Weight applied to the engine mani-
fold can result in manifold damage.
the
mufflerand exhaust piping
so
no weight
or
stress is applied to the engine exhaust manifold.
Avoid sharp bends by using sweeping, long radius
elbows and provide adequate support for mufflers, and
tailpipe. Pitch a horizontal run of exhaust pipe
DOWNWARD to allow any moisture condensation to
drain away from the engine. If an exhaust pipe must be
turned upward, install a condensation trap at the point
where the rise begins (see Figure 5).
Page 10
AVOID
SHARP
BENDS
IF EXHAUST LINE MUST BE PITCHED UPWARD.
CONSTRUCT A TRAP OF PIPE FITTINGS AT
POINT OF RISE
Dampers
Dampers
are
used
in any
system
to
block
the
airflow
through the vents when the generator set is not running.
This
is
sometimes necessary
the generator enclosure
in
cold climates
at a
normal temperature.
to
keep
Radiator Set
Radiator set cooling
air
is drawn past the rear of the set
by a fan which blows airthrough the radiator. Locate the
air inlet
inlet vent opening 1 -1
to
the rear
of
set and near the floor. Make
/2
times larger than the radiator.
the
DRAIN CONDENSATION TRAP
PERIODICALLY
EXS-1046
FIGURE S. EXHAUST CONDENSATION TRAP (TYPICAL)
Shield.or insulate exhaust lines
personal contact. Allow
clearance
if
the pipes pass close to a combustible wall
at
least
if
there
is a
12
inches (305 mm)
danger
of
of
or partition.
VENTILATION
Generator sets create considerable heat that must
removed
rely
need properly sized
required airflow. Refer
T-030,
Vents
For indoor installations, locate vents
passes through
before exhausting. Install the
air inlet
ure 1
Size
allow
ducts must
by
proper ventilation. Outdoor installations
on
natural
for
additional application information.
and
Ducts
to
allow
for a
typical installation).
the
vents
the
required flow rate
be as
air
circulation
and
the
immediate area
for
convection
and
ducts
large
SYSTEM
but
indoor installations
positioned vents
to
Onan Technical Bulletin,
so
of
the installation
air
outlet higher than
air
movement (see
so
they
are
large enough
of air. The
as the
exposed area
for the
incoming
"free area"
of the
be
air
the
Fig-
to
of
radiator. Refer to the DFE series Product Data Sheets for
the airflow requirements.
Wind will restrict free airflow
air outlet vent. Locate
the
outlet vent
if it
blows directly into the
so the
effects
of
wind are eliminated.
For operation outside a building, a shelter housing with
electrically operated louvres
Transformers connected across
supply current
When
the
to
the motors.
generator
is
formers actuate the motors and open
louvres are held open for the duration
tion,
then
are
closed
by
is
available
the
as an
generator output
operating, current
the
of
the set opera-
return springs when
option.
in the
louvres.
the set is
trans-
The
shut down.
Locate the cooling air outlet directly in front ofthe radiator and as close as possible. The effective opening area
should be 1.3 times as large as the radiator
and shape
restriction
of
to
the
air
airflow.
outlet duct should offer minimum
Use a
duct
of
canvas between the radiator and the
to prevent recirculation
flexible connection.
Heat Exchanger
of
heated
air and
^
*
area.
sheet metal
air
outlet opening
provide
Length
and
for
Heat exchanger cooled sets do not use a conventional
radiator. Instead, a constantly changing water flow
cools the heat exchanger which in turn cools the engine
coolant. Sufficient
available
to
disperse heat
To provide sufficient airflow, ventilation fans
required.
Size the fans to remove all heat rejected to the
room by the generator
producing equipment. Maintaining a temperature
ferential
of 20° to
air
movement and fresh
radiated
set,
30°F
from
exhaust pipes and other heat
(11° to 170C) is
air
must
be
the heat exchanger.
may be
dif-
usually
satisfactory.
COOLING
A
set
mounted radiator with engine driven fan
dard
on the
include remote radiator cooling
generator
SYSTEMS
set.
Optional cooling systems
and
heat exchanger
is
stan-
cooling.
The following sections briefly cover
requirements
letin T-030
Standard
for
each system. Refer
for
more detailed information.
Radiator Cooling
The standard radiator cooling system
uses
a set
pusher type fan
mounted radiator with
to
cool the generator set.
the
installation
to
Technical
(see
Figure
an
engine driven
Air is
Bul-
1)
pulled
from the generator end of the set across the engine and
then forced through
flange surrounds the radiator grill
the
air
discharge duct. Refer
tion
for
location and sizing
the
radiator.
An air
to
to
the section
of
ducts and vents.
duct adapter
allow mounting
on
Ventila-
of
Page 11
Remote Radiator (Optional)
Remote radiators can be located a horizontal or a
cal distance, from an engine. The horizontal distance is
limited by the capability of the engine driven water pump
and the maximum external Friction Head pressure. The
vertical distance is limited to the maximum Static Head
pressure which can be imposed on coolant system
gaskets and seals without leakage of coolant from coo-
lant system components. The Friction and Static Head
pressures of each GenSet are included in their Product
Data Sheet.
The two key design considerations in a remote radiator
installation are the vertical distance (X) from the engine
centerline to the radiator top and the horizontal distance
(Y)
from the engine front to the radiator centerline (see
Figure 6). These distances determine if any additional
equipment is required such as a surge tank, auxiliary
pump,
or hot
well.
Because of the many design considerations, all remote radiator installations must be
neered to insure that the system will function properly.
Follow the instructions of the consulting engineer when
installing a remote radiator system-Additional informa-
tion is contained in Technical Bulletin T-030.
Heat
Exchanger
This cooling system uses a shell and tube type heat
exchanger instead ofthe standard radiator and fan (see
Figure 7). Engine jacket coolant circulates through the
shell side ofthe heat exchanger, while the cooling water
is pumped through the tubes. Engine coolant and raw
water do not mix. This type of cooling separation is
necessary when the raw water contains scale forming
lime,
or other impurities.
FILLER
(Optional)
7 PSI MINIMUM (48 kPa) PRESSURE CAP
verti-
engi-
This system can reduce set enclosure airflow requirements and noise levels. Proper operation depends on a
constant supply of raw water for heat removal. Adjust
the flow to maintain water temperature between 165°
and 1950F (74° and 910C) while viewing the water
temperature gauge. The engine coolant side of the system can be protected from freezing; the raw water side
cannot be protected.
All heat exchanger cooled sets must be connected to a
pressurized supply of cold water. Make connections to
the set with flexible pipe to absorb vibration. On the cool
water line, install a solenoid valve to shut off the flow
when the set is shut down and a rate of flow valve to
control engine temperature. This valve can be either
manual or automatic. Actual rate of flow will depend on
inlet water temperature.
Adjust the valve to maintain water temperature between
165° to 195° F (74° to 910C) while operating the unit at
full
load.
Before filling cooling system, check all hardware for
tightness. This includes hose clamps, capscrews, fit-
tings and connections. Use flexible coolant lines with
heat exchanger or remote mounted radiator.
ENGINE
GENERATOR SET
C
m
FIGURE 6. REMOTE RADIATOR INSTALLATION
9
CS-1130
Page 12
EXPANSION TANK
Coolant
A
coolant heater is
Heater
when the engine
coolant
and
electrically
within
lessens
engine wear
operated and thermostatically controlled.
(Optional)
used
to keep engine coolant
is
shut
down.
the engine.
It
heats
This
reduces
caused
and
circulates
start-up
by cold
warm
starts.
the
time
It is
DRAIN
MANUAL OR AUTOMATIC
WATER.TEMP-CONTROL.
Coolant
One
equipment.
VALVE
FIGURE
7.
TYPICAL
Filter
spin-on typexorrosion
This
precharge
water and all ethylene glycol
freeze
coolants.
Referto engine manufacturer's manual
STRAINER^
HEAT
EXCHANGER
filter
(Figure 8) is standard
filter
is
compatible
base
for instructionslfa methoxy propanal
desired.
MAINTENANCE
Replace>filter periodically as
section
of Operators Manual.
'WATER
• IN;
CS-1075
with
plain
permanent anti-
base
anti-freeze
recommended;
is
in
ACAUTION
when the engine is running
The heater must not be operated
while the cooling system is empty
or,
damage
to the heater-will
occur.
Figure 9 shows the the heater line connections. Connect the. heater to a source of power that will be on
during the time the engine is not running. Be sure the
voltage rating is correct for the heater element rating. -
WATER HEATER
OUTLET
HEAD AND
VALVE ASSY
FIGURE
ELEMENT
9.
TYPICAL
OIL PLUG
COOLANT
- - WATER
DRAIN COCK
HEATER
HEATER
INLET
or
COOLANT FILTER-
SHUT-OFF VALVE
FIGURE
8.
TYPICAL
SPIN-ON
COOLANT FILTER-
SHUT-OFF1 VALVE
BATTERY CHARGING
ALTERNATOR
COOLANT
FILTER;
10
Page 13
Electrical
Connections
GENERAL
The generator set electrical system installation includes .
connecting the
connecting the batteries. The batteries should be
nected last to avoid accidental starting of the unit during
installation.
load,
installing the control wiring, and
con-
AC
WIRING
Generator Voltage
The generator output voltages and maximum current
rating is specified on the generator nameplate. Line-toneutral voltage is always the lower voltage shown onthe
nameplate and line-to-line voltage is the higher rating.
Connections
Most local regulations require wiring connections bernade by a licensed electrician and the installation must
be inspected and approved before operation. All
nections, wire sizes, etc. must conform to the requirements of all electrical codes in effect at the installation
site.
AWARNING
If the installation is for standby service, a transfer switch
is required for switching the load from the normal power
source to the generator set (see Figure 10). Either a
manual or automatic transfer switch may be used.
low the installation instructions provided with the
transfer switch when connecting the load and control
wiring.
generator rating.
Onan supplied transfer switches match the
NORMAL
SOURCE
Improper wiring can result in fire and
severe personal injury or death.
TRANSFER
SWITCH
LOAD
GENSET
con-
Fol-
Generators can be divided into two groups, reconnectible and non-reconnectible. The reconnectible type
generator can be wired to give one of several possible
voltages. Non-reconnectible type generators produce
only one specific voltage and cannot be wired to give a
different voltage without extensive modifications. The
following sections explain the connection procedure for
each voltage code.
Non-Reconnectible Generators (Voltage Codes 6D,
7R, and 9X): These generators are wired at the factory
for a specific voltage and are not intended for reconnection.
The voltage and corresponding current rating
(amperes) are shown on the nameplate.
Reconnectible Generators (Voltage Codes 15 and
515):
Generators with codes 15 (for 60 Hertz) and 515
(for 50 Hertz) are three phase generators that can be
reconnected for any of the voltages shown in Figure
Refer to the set nameplate for the corresponding current
rating (amperes).
Load
Connections
The 12 lead generators with load connection wires ARE
NOT connected together in the output box when
shipped from the factory. These 12 wires are labeled T1
through T12 and must be brought together before mak-
ing load connections. Proceed as follows:
11.
FIGURE 10. LOAD TRANSFER SWITCH
(TYPICAL FUNCTION)
1.
Remove the right or left panel from output box. .
2.
Bolt the load wires to the appropriate generator lead
wires in the output box according to Figure 11 for
required voltage.
3. Insulate the connections.
11
Page 14
if-/
220/380 VOLT, 3 PHASE,
347/600 VOLT, 3 PHASE,
GENERATOR
CONNECTION.
SCHEMATIC
DIAGRAM*
60
HERTZ
60
HERTZ
GENERATOR CONNECTION WIRING DIAGRAM
(WITH CURRENT TRANSFORMERS WHEN USED)
15;
:ii5
sis:
SIS
120/240 •'
US/230
1TO/220
\3:B/.T»B.
ll!S/2:3:0
1.T0/Z20
12.0/20.8
uyiAo.
1:10/1.9
0.
115/20.0
nq/ios:
UT/220
24o/*l,6.
254/440
2Z7/48.0
22X^3801
2 3 0/4 Ott
2:40/4«l,6.
•2
S-4/4.4
0
f X
: IT.
6.0.
soe
so;
6.0
60:
e>S>:
[iXK
SO:
SO
'so;
6.0;
60;
6.0;
SO
5 0;
SO;
SO
t3r
TV
TIO' T6 T7 17. Til
to.
11
C.T21
TS
TIO.' TI2
1.a,
11
\.
CT21
TIO;T
li
TT
2: TT. T7 T4i TT.
CT22
CT22
T-41T81
T3 T12 TS
TS*
T5 T3,
9aC2l93.
CT24
CT23'
C
T24
13
T 3
T9
FIGURE
11.
GENERATOR VOLTAGE CONNEG.TIONS
12
Page 15
When installing sets with the optional AC ammeter, the
generator output leads must be routed through a current
transformer for proper meter operation (See Figure 12).
The transformers are identified
CT21,
CT22, and CT23
(three phase only) on the wiring diagram and electrical
schematics. Refer to Figure 11 to identify the output
leads that must be routed through each transformer.
Use a cable tie to secure the loose transformer to the
generator output leads.
connected.
Any combination of single phase and three
phase loading can be used as long as each line current
is about the same, within 10 percent of median value,
and no line current exceeds the nameplate rating of the
generator. Check the current flow from each line after
connections by observing the control panel ammeter.
Grounding
Grounding involves making a conducting connection
between the metal parts of the generator set or one of its
electrical circuits and the
earth.
The design and installa-
tion of a grounding system is affected by many factors
such as the use of multiple transformers, ground fault
protection requirements, and physical location of the
generator. Follow the recommendations ofthe consult-
ing engineer when installing the grounding system.
CURRENT TRANSFORMERS
FIGURE 12. CURRENT TRANSFORMERS
Load
Balancing
When connecting loads to the generator set, balance
the loads so the current flow from each line terminal
L2,
and L3) is about the same. This is especially impor-
(L1,
tant if both single phase-and three phase loads are
AWARNING
Confacf with electrical equipment
can result in severe personal injury
or death. It is extremely important that bonding and
equipment grounding be properly done. All metallic
parts that could become energized under abnormal
conditions must be properly grounded.
Control Heater (Optional)
A control heater provides a means of humidity/temperature control of the control box interior to protect the
components and ensure their effectiveness when the
generator set is subjected to varying ambient air conditions during extended periods of non-use (see Figure
13).
The element is controlled by an adjustable
thermostat.
FIGURE 13. CONTROL HEATER
13
ES-1563-3
Page 16
DC WIRING
Remote Control Connections
. Provisions are made inside the control box fbr addition
- of optional remote.startlng^awd af
made on theterminal bJook
monitor oireuit board {A-l
amjs.
Gonnectionsare
<TB1)
located on the engine
1|.
Connect
one or
more
'•remote switches across remote terminal and S*/termi-
nal (See Figure 14).
If the distance betweenvihe generator set aiad remote
sstationsHS less;than?1©©01eet^305 mm), use 1i8 gauge
strandedcopperwirei^the^^distocefe1©0Gtb^OO0feet
(305
to 610
••«lkViimys:
"ffomithe AG^powe^s<»b*es
m);
use.>
1$ gauge stranded oopper wire.
mfumritft&cSSto^v&finQfa ^separ^chmdyift;
lo
avoid:
aindacing
c\jiTenfe
^h"atrc0uldiCause5pTia>i©(ns wftlwh ^ecmj*©!;
S^OC POWER)
Remote Monitor Connections
Provisions are made inside the control box for addition
of optional remote monitoring
on
these generator sets
employing optional Detector 12 Control (12 light panel).
Connections
are
made
on the
terminal block
(TB2)
located on the engine monitor circuit.board (A11).
ACAUTION
Do Not install DC control wiring in the
same conduit
as the AC
power.'AC
voltage induced,currents can create operational prob-
lems with electronic solid-state devices.
•.
i:
TB2
1
FAULT
2 -
INPUT
1
NON-TIMED
EAULT
2 •
2-
FAULT.1 - INPUT
;:3-
•
4
FAULT 1 -
LAMP TEST/RESET
5
OVERCRANK
6
7
OVERSPEED
8
•
HIGH ENGINE TEMPERATURE
.9
:
LOW OIL PRESSURE
10 PRE-KIGH ENGINE TEMPERiATUIBE
11
PRE«W OIL PRESSURE
12 SWITCH OFF
13
LOW ENGINE TEMPERATURE
14
LOW FUEL - INPUT
15 LOW FUEL - OUTPUT
•SHUT-OOWN
16
OUTPUT
OUTPUT
i
..SHUTDOWN
\
i
-
TIMED
SHUTDOWN
ENGINE
CONTROL
•MONITOR
•All
FfSURE 14. REMOTE CONTROL AND REMOTE MONITOR CONNECTIONS
14
XES-1S61
Page 17
Battery
Connections
Starting the unit requires 24-volt battery current. Use
two 12-volt (see SPECIFICATIONS) batteries for a normal installation. Connect the batteries in series (negative post of first battery to positive post of second) as
shown in Figure 15. Normal installation battery cables
are included. Increase the cable size if batteries are
located remotely from generator set. Service the batter-
ies as necessary. Infrequent unit use (as in emergency
standby service) may allow the batteries to selfdischarge to the point where they cannot start the unit. If
installing an automatic transfer switch that has no built-
in charge circuit, connect a special float charger.
AWARNING
Ignition of explosive battery gases
can cause severe personal injury. Do
not smoke while servicing batteries.
STARTING MOTOR
SOLENOID
CONNECT NEGATIVE CABLE TO
CONVENIENT BOLT ON ENGINE
THE CONNECTION MUST BE CLEAN
AND PAINT FREE
FIGURE 15. BATTERY CONNECTIONS
BATTERY POSITIVE
CONNECTION
2-12 VOLT BATTERIES
15
Page 18
Bef ore attem pti n g theira^itia'ls'tafti ng^tteseieneFator^,
be?
sure it is servicediatsel fre'adyffOT*oiDerationJFill Sftre
coolant; I u
brication:and;fu^lfs^teTns:aTid;pwm^^
riGation-and fuel systfems. - '
mmmm
Engine coolant is driii^^tor^^ipwerttlB^teFre^ta'fti
ng,
f i
11
the coolant system ^withlthie-reGOmmended
ant per the Opera\m^Mmiia\MMN^NMN'G'£s$ee\\m,
Coolant instructions:
LUBRICATION
Engine lubricationJissdrained• priorttorshipment.SBefore
starting,
follows:
1.
2;
3. Remove plugSromth-eadcdffdMN
4.
5. Disconne£tmite ftfiotn
6. Remove ^^•nSl-^i'm^a^^weTtt.a^a^^lLig
7. ReconnebtiW.ire«to3oel^huKdff^valve.
'8.
fill and primeStheHubricatiO^
Remove-oil
(Fig u re
M'nlet^litfiBffrotnft^^e^aiseTlhrocrsin®
16),
MI sbearing ^housing with
«5le"an
lubricatingidil^-replaeeiline.fsecure.
Fill crankcase^to "L''f(teW)wa;r^^n--dip^ti^(Sigure
17) .
16)
and connectva "hand tor rmdtONdriven ipiming
pump from5a?sot»ee«ffasteaia'UI&BB^fcfig«>ilft©^h'e
plug 'boss?inEfjlter.!h*oasihg-
Prime antH^Bpsl^Yik^lS^smfe-'iS^^linBd.
Steel
«ote'n'0id *val«e IPigure
18)
, closethT^ttlewd^rawk^Tg^newSile^iri
ing an^exfei^l^infep^i^^^spsi^i^^i,
for 15 seconds.
in filter hoUSihgand^oiXiu^to1^to^?ft.'lbi(2t)itoS7
N«m).
Complete«n9illfto^Hl^l3)^atk«i^^^tic1<.
codl-
^engine
COI.L':SURPLY INLET LINE. '•
HDISC-'ONNECT AT THIS
'POINT TO PRIME
.78 34 2-3
FIGURE 16. PRIMING TURBOCHARGER
•OIL
03 fP "STICK
•EXHAUST
CONNECTION
T—rTURBO^CHARGER
HOUSING* • .
FlUT-ER
•:0I.LfFIL'L
FIGURE
S17..
30IUFILI. ANDiOIRSTIGK'liOCATlONS
Page 19
FUEL SOLENOID
VENTILATION
Verify all air vents and ducts are open and free of
any obstructions. Verify dampers, if used, operate
properly.
FIGURE 18. FUEL SOLENOID VALVE LOCATION
FUEL
SYSTEM
Engine fuel may not be primed at the fuel filters after
shipment. To verify and reprime the fuel system perform
the following procedure:
1.
Remove each fuel filter (Figure 19) and fill with clean
fuel.
2.
Put a light coat of fuel on the sealing gasket.
3. Install and tighten by hand until the gasket just
touches the filter head.
4.
Tighten the filter an additional one-half to three-
fourths of a
turn.
EXHAUST
SYSTEM
Check the exhaust system for proper installation.
Verify there is at least 12 inches (305 mm) clearance
between exhaust pipes and any combustible
materials.
ELECTRICAL
SYSTEM
Verify all electrical connections are secure and all
wiring is complete. Replace and secure any access
panels that may have been removed during installation.
Battery
Connections
Use two 12-volt batteries for a normal installation.
Connect positive battery cable before connecting
negative battery cable to prevent arcing.
Service the battery as necessary. If an automatic
transfer is not used or is installed without a build-in
charge circuit, connect a separate trickle charger to
the battery.
Load
Connections
Check that load cables from generator set are properly connected to either a transfer switch or circuit
breaker panel.
SUPPLY LINE,
FILTER TO
INJECTION PUMP
FUEL SUPPLY
FUEL FILTERS
FIGURE 19. FUEL FILTERS
NLET
MECHANICAL
CHECK
Check the generator set for loose or damaged com-
ponents and repair or replace as required.
17
Page 20
Initial
Before putting the generator set under load conditions,
verify the generator set will perform'correctly by checking the following areas.
Start and
Checks
STARTING
Move the Run/Stop/ Remote switch on the engine
trol panel to the
the engine and the engine should start within a few
seconds. If after a few seconds of cranking the engine
fails to start or starts, runs, and then stops and the fault
lamp lights, refer to the Troubleshooting chart in the
Operators Manual.
Check the following while the generator set is operating.
Oil
Pressure
The oil pressure should be in the range of 50 to 70 psi
(345 to 483 kPa) when the engine is at operating
temperature.
Water
Temperature Gauge
195° F (74? to91 ''CJ depending'on theloadandambient
The water temperatureshouldbein the rangeof•'T=650 to
temperature.
RUN;
ENGINE
Gauge
position.
GAUGES
Ihe starter should crank
con-
AC
Voltmeter
Turn the phase selector switch to each line-to-line
phase selection shown on the volts scale (L1-L2 on
single phase sets: L1-L2, L2rL3, and L3-L1 on three
phase sets). Read the AC voltmeter using the upper or
lower scale as indicated by the scale indicator light. At
no
load,
the line-to-line voltage should be the same as
the set nameplate rating.
AC
Ammeter
Turn the phase selector switch to each phase selection
shown on the amperes scale
sets;
L1, L2, and L3 on three phase sets). Read the
ammeter using the upper or lower scale as indicated by
the scale indicator light. At no
should be zero. With a load applied, each line current
should be approximately the same and no line current
should exceed the set nameplate rating.
ENGINE
Move the Run/Stop/Remote switch on the engine
panel to the stop position. Hold the Reset/Lamp Test
switch in the Test position. All indicator lamps should
light. Verify all of the lamps are on and then release the
switch.
replacement.
MONITOR INDICATOR
Contact an Onan distributor if any lamps require
(L1
and L2 on single phase
load,
the current readings
LAMPS
DC
Ammeter
The maximum charge rate for the set mounted battery
charging alternator is 35 amperes. Charge rate should
taper to zero following start-up as battery becomes
charged.
AC
METERS
Note the AC instruments on the control panel. The fre-
quency meter and voltmeter should indicate rated
nameplate frequency and voltage. Turn the control
panel Voltage Adjust control (if equipped) for nameplate
voltage. Use the Phase Selector Switch to read each of
the line-to-line voltages.
If unit does not have control instruments or a Voltage
Adjust control on the front panel, proceed to Generator
Voltage Checks section of this manual.
Check
the following while the generator
Frequency
The generator frequency should be stable and the reading should be the same as the nameplate rating (50 or 60
Hz).
Meter
(IF
EQUIPPED)
set
is
operating.
G EN
ERATOR
Generator voltage checks consist of two possible
procedures dependent on generator set meters (Detec-
tor AC Option).
The generator voltage may be adjusted within 5% of the
rated nameplate voltage through external control panel
mounted or internal voltage regulator mounted potentiometers. The internal potentiometer also adjusts the
range of the external potentiometer.
Movethe Run/Stop/Remote switch onthe engine
trol panel to the Run position. Check the following while
the generator set is operating.
Generator Voltage Adjust (Detector AC Option)
This procedure pertains to generator sets equipped
with Detector AC option only. The AC option consists of
meters, switches and a voltage adjusting R21 potenti-
ometer on the control front panel.
1.
Operate Phase Selector switch to read generator
output current and voltage and perform the following steps:
A. Insert a screwdriver into the Voltage Adjust R21
potentiometer located on the front of the generator set control and using a wrench carefully
loosen the locking nut.
VOLTAG E CHECKS
con-
18
Page 21
B. While observing
screwdriver clockwise
counterclockwise
adjust
to the
i
If
correct voltage cannot
this adjustment, proceed
Adjustment procedure.
C. After setting^conrect
nut being carefuJ.not
2.
Operate Phase Selector switch
Voltage Regulator Adjustment
This procedure pertains
with Detector
the adjustment range centering
potentiometer located
1.
Operate Phase Selector switch
output current and voltage and perform
ing steps:
A.
B.
AC
option only.
Insert a screwdriver'into
potentiometer located on the front of the genera-
tor
set
control
loosen
the
Turn screwdriver to set adjustment screw
mid-position
careful
not to
AWARNING
hazard which
injury
or
death.
the
voltmeter, slowly turn
to
to
"decrease voltage,
rated nameplate voltage.
to
.voltage,
to
change
to
generator sets equipped
The
of
on the
locking
and
change
control front panel.
the
and
using a wrench carefully
nut.
retighten locking
the
adjustment.
High voltages
present
can
Proceed with care!
an
cause severe personal
the
increase voltage
be
attained through
Voltage Regulator
retighten locking
the
adjustment.
to the Off
procedure performs
voltage adjust
to
Voltage Adjust
electrical shock
position.
read generator
the
nut
in the
or
and
R21
follow-
R21
to the
being
control
C. Open control panel doors, locate VRAS-2
(upper
left),
and
refer
to
Figure
potentiometer.
D. While observing
driver into
increase
the rated nameplate voltage.
2.
Close control panel doors
Selector switch
Generator Voltage Adjust
(Without
This procedure pertains
generator set that does
Detector
or
AWARNING
cause severe personal injury
care!
1.
Open control panel doors, locate VRAS-2 (upper
left),
and
refer
TBI
and R32
2.
Connect
minal board
3. While observing
into
R32
or decrease voltage until adjusted
nameplate voltage.
4.
Disconnect voltmeter from
panel doors.
potentiometer.
an
accurate 2% voltmeter
TB1
potentiometer
GENERATOR
The generator frequency
which
is
automatically controlled.
quency
tor.
is
below specification contact an Onan distribu-
the
voltmeter, insert a screw-
R32
potentiometer and slowly turn
decrease voltage until adjusted
to the Off
AC
not
High voltages
an electrical shock hazard which can
to
Figure
-2
the
position.
Option)
to the
voltage adjustments
have the Detector AC option.
or
20 to
and TBI
voltmeter, insert a screwdriver
-3
and
TB1 and
FREQUENCY CHECK
is a
result
20 to
locate
and
operate Phase
in the
slowly turn
control present
death. Proceed with
locate terminal board
to
VRAS-2 ter-
terminals (Figure 20).
to
increase
to the
close control
of
engine speed,
If
generator fre-
R32
to
to
of a
rated
19
Page 22
VERTICAL CONTROLLER
TIME DELAYED START/STOP
ENGINE
VOLTAGE CONTROL
REGULATOR MONITOR
VRAS-2
A11
\
\
AND PREHEAT Al 5
INDICATOR
LAMPS A-12
MAGNETIC
PICKUP
A16
VOLTAGE REGULATOR VRAS-2
RUN RELAY
--"Kl 1 INTERFACE
RELAYMODULES VOLTAGE SENSOR
STABILITY
STABILITY
RANGE
RANGE
S1-1
ON
SI-2
ON
OVER/UNDER
A'l 7
FIGURE
TORQUE-MATCHING
S2 S3-1
POS 2 OFF
20.
TABLE
60 Hz
VRAS-2
2.
XES-1561
R32
VOLTAGE
VRAS-2
S3-2 S2 S3-1
ON
REGULATOR
SWITCH
REGULATION
50 Hz
TORQUE-MATCHING
POS 2 ON ON
TBI-2
ASSEMBLY
SETTINGS
MODE
S3-2
TBI-3
NON-
TORQUE-MATCHING
S2 S3-1
POS 2 OFF
S3-2
OFF
• Switch
the regulator. Refer
• Switches
SI -
Selects the overall range of operation for
to
Table
2.
S2 and S3 -
Determine
the
mode
regulation (Torque-Matched, or Non-Torque-Matched).
Refer
to
Table
2.
• Potentiometer
crease
or
R32 -
Provides adjustability
decrease generator voltage
to
achieve
to in-
proper setting.
• Potentiometer R34
the frequency breakpoint,
- Is
adjusted
and
at
the factory
does
not
to set
require
further adjustment
20
of
Page 23
EXHAUST
With the generator set operating, inspect the entire
exhaust system including the exhaust manifold, muffler,
turbocharger and exhaust pipe. Visually and audibly
check for leaks at all connections, welds, gaskets, and
joints.
Make sure exhaust pipes are not heating surrounding areas excessively. If any leaks are detected,
have them corrected immediately.
AWARNING
death. Inspect exhaust
leaks daily. Repair any leaks immediately.
Inhalation of exhaust gases can
result in severe personal injury or
FUEL
With the generator set
lines,
filters, and fittings for leaks. Check any flexible
sections for cuts, cracks, and abrasions and make sure
they are not rubbing against anything that could cause
breakage.
AWARNING
injury or death if ignited by a spark. If any leaks are
detected, have them corrected immediately.
With the generator set off, check the terminals on the
battery for clean and tight connections. Loose or
corroded connections create resistance that can hinder
starting.
Always connect the negative battery cable last.
Clean and reconnect the battery cables if loose.
Leaking fuel will create a fire hazard
that can result in severe personal
DC
ELECTRICAL
SYSTEM
system
SYSTEM
operating,
audibly and visually
inspectthe fuel supply
SYSTEM
for
AWARNING
not smoke while servicing batteries.
When the engine is first started, remove the pressure
cap and monitor the coolant level. As trapped air is
expelled from the
additional coolant should be added. Replace the
pressure cap when the coolant level is stable.
AWARNING
to cool before releasing pressure and removing the
radiator cap.
MECHANICAL
With the generator set stopped, check for loose belts
and fittings, leaking gaskets and hoses, or any signs of
mechanical damage. If any problems are found, have
them corrected immediately.
With the set running, listen for any unusual noises that
may indicate mechanical problems and check the oil
pressure frequently. Investigate anything that indicates
possible mechanical problems. Refer to the Operators
Manual for any necessary adjustments.
Ignition of explosive battery gases
can cause severe personal
COOLING
system,
Contact
severe burns. Allow cooling system
SYSTEM
the coolant level will drop and
with
hot coolant can result in
injury.
ADJUSTMENTS
Dp
21
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I
Onon
Onan Corporation Telephone: (612) 574-5000
1400 73rd Avenue N.E. Telex: 275477
Minneapolis, Minnesota 55432 Cable ONAN
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