Onan DJB, DJE Owner's Manual

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Page 1

Operator’s Manual

GenSets

Electric Generating Sets

967-0121

2-91

Printed in U.S.A.

Page 2

Table of Contents

SECTION TITLE PAGE

SAFETY PRECAUTIONS Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 GENERAL INFORMATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Identification 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 SPECIFICATIONS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3 CONTROL DESCRIPTION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control Panel Components 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage Reconnection with Optional Instruments 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . .

4 INSTALLATION 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Installation Requirements 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Set Location 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mounting 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank and Lines 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Injection Pump Adapter Assembly (DJE only) 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Drain 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Connections 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Balancing Loads 4-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Switchboard 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reconnectible Generators 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Connections 4-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Alarm 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Start-Stop Switch (Optional) 4-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 OPERATION 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Starting 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Heating and Starting 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Automatic Starting and Stopping 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Applying Load 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust System Inspection 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break-In Procedure 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Devices 5-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercising Unit 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Ratings 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High/Low Operating Temperatures 5-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dust and Dirt 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Altitude 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Out-of-Service Protection 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Returning the Set to Operation 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 ADJUSTMENTS 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centrifugal Switch 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Charge Rate Adjustment 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve Clearance Adjustments 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page 3

SECTION TITLE PAGE

7 GENERAL MAINTENANCE 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Periodic Checks 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Filters 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Linkage 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Breather Tube 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Crankcase Breather 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cooling System Maintenance 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Pump Sediment Bowl 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air Cleaners 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contractor Model Air Cleaner 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Optional Oil Bath Air Cleaner 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter Change 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 PERIODIC MAINTENANCE SCHEDULE 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety Precautions

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 precau- tions.

The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service per- sonnel, or the equipment.

This symbol warns of immediate haz- ards 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 prod- uct or property damage.

FUEL AND FUMES ARE FLAMMABLE. Fire and explosion can result from improper practices.

• 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 ap- proved flexible line. Do not use copper piping on flexible 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 GASES ARE DEADLY

• Provide an adequate exhaust system to properly expel

discharged gases. Visually and audibly inspect the ex- haust daily for leaks per the maintenance schedule. En- sure that exhaust manifolds are secured and not warped. Do not use exhaust gases to heat a compartment.

• Be sure the unit is well ventilated.

MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH

• Keep your hands, clothing, and jewelry away from moving

parts.

• Before starting work on the generator set, disconnect

starting batteries, negative (-) cable first. This will prevent accidental starting.

• 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 mov-

ing 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 SHOCK CAN CAUSE SEVERE PER- SONAL INJURY OR DEATH

• 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 equip- ment.

• 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 voltages 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 isolation switch or an approved paralleling device.

GENERAL SAFETY PRECAUTIONS

• Coolants under pressure have a higher boiling point than

water. DO NOT open a radiator or heat exchanger pres- sure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first.

• 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.

• Provide appropriate fire extinguishers and install them in

convenient locations. Consult the local fire department for the correct type of extinguisher 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. Ac-

cumulated 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

fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe.

LS-9

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Section 1. General Information

This manual contains information on operating, maintaining, and adjusting the Onan® DJB and DJE genera- tor sets. Study and follow these instructions carefully. A well-planned service and maintenance program will help provide longer unit life and better performance.

In this manual, the engine end of the generator set is de- fined as the front. The “left” and “right” sides are defined when facing the engine (front) end.

HOW TO OBTAIN SERVICE

When the generator set requires servicing, contact your nearest dealer or distributor. Factory-trained Parts and Service representatives are ready to handle all your service needs.

If unable to locate a dealer or distributor, consult the Yel- low Pages. Typically, our distributors are listed under:

GENERATORS-ELECTRIC, or ENGINES-GASOLINE OR DIESEL

For the name of your local Cummins®/Onan or Onan- only distributor in the United States or Canada, call

1-800-888-ONAN (this automated service uses touchtone phones only). By entering your area code and the first three digits of your local telephone number, you will receive the name and telephone number of the distribu- tor nearest you.

When contacting your distributor, always supply the complete Model Number and Serial Number as shown on the generator set nameplate.

Onan gensets are given a complete running test under a variety of load conditions, and are thoroughly checked before leaving the factory. Examine this unit closely when it arrives, for possible shipping damage. Tighten loose parts, replace missing parts and repair all visible damage before starting the unit.

MODEL IDENTIFICATION

When this manual refers to a specific generator set, iden- tify it by referring to the MODEL and SPEC NO. shown on the unit nameplate. Electrical specs are listed on the lower portion of the nameplate.

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Page 6

Section 2. Specifications

DJB GENERATOR SETS: 4.5 (50 HZ) AND 6.0 (60 HZ)

DIMENSIONS

Height 28.94 inches (735 mm) Length 36.69 inches (932 mm). . . . . . .

Width 21.75 inches (552 mm) Weight 485 lbs (220 kg). . . . . . . .

INSTALLATION REQUIREMENTS

Fuel pump inlet thread size 7/16-24 NPTF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump maximum lift 6 ft (1.83 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust outlet (pipe tapped) 1.25 inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum exhaust back pressure 27 inches (686 mm) H Ventilation required (60 Hz) Engine (Vacu-Flo cooling) 560 cfm (15.9 m

(60 Hz) Generator 160 cfm (4.53 m (1800 rpm) Combustion 25 cfm (0.7 m (50 Hz) Engine (Vacu-Flo cooling) 467 cfm (13.2 m (50 Hz) Generator 133 cfm (3.8 m (1500 rpm) Combustion 21 cfm (0.6 m

BATTERY AND STARTING SYSTEM

O (6.7 kPa). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . .

Starting system voltage 12 volts Battery charge rate 2-5 amps. . . . . . . . . . . . .

Battery requirements:

Temperature Quantity Volts BCI Group Cranking Performance Amp.Hr.Capacity

Range Size at 0° F (-17° C) (20 hour rate)

32° F (0° C) and warmer 2 6 1 450 amps 105

0° F (-17° C) and warmer 2 6 2 560 amps 135

-25° F (-32° C) and warmer 2 6 5D 800 amps 190

GENERATOR

Rating (AC output): 4.5 DJB (50 hz) 4.5 kW 6.0 DJB (60 hz) 6.0 kW. . . . . . . . . . . . . . . .

ENGINE

Number of cylinders (vertical in-line) 2 Displacement 60 in3 (984 cc) . . . . . . . . . . . . . . . . . .

Cylinder bore 3.25 in. (82.55 mm) Piston stroke 3.625 in. (92.1 mm). . . . . . . . . . . . . . . . .

RPM 60 Hz: 1800 rpm 50 Hz: 1500 rpm. . . . . . . . . . . . . . .

Oil capacity 3 U.S. quarts plus 1/2 quart for filter. . . . . . . . .

Fuel consumption (60 Hz set) (50 Hz set)

Full load 0.64 gph (2.42 L/h) Full load 0.53 gph (2.0 L/h). . . . . . . . . . . . . .

3/4 load 0.53 gph (2.01 L/h) 3/4 load 0.45 gph (1.70 L/h). . . . . . . . . . . . . . .

1/2 load 0.43 gph (1.63 L/h) 1/2 load 0.38 gph (1.44 L/h). . . . . . . . . . . . . . .

1/4 load 0.33 gph (1.25 L/h) 1/4 load 0.27 gph (1.02 L/h). . . . . . . . . . . . . . .

ADJUSTMENT SPECIFICATIONS

Cylinder head bolt torque 44 - 46 ft-lb (60 - 62 n•m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow plug torque 10 - 15 ft-lb (14 - 20 n•m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve clearances Intake: 0.009 in. (0.229 mm) Exhaust: 0.007 in. (0.178 mm). . . . . . . . . . .

Centrifugal switch breaker point gap 0.020 inch (0.508 mm). . . . . . . . . . . . . . . . . . . . .

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Page 7

DJE GENERATOR SETS: 4.5 (50 HZ) AND 6.0 (60 HZ)

DIMENSIONS

Height 26.12 inches (663 mm) Length 33.44 inches (849 mm). . . . . . .

Width 18.38 inches (467 mm) Weight 485 lbs (220 kg). . . . . . . .

INSTALLATION REQUIREMENTS

Fuel pump inlet thread size 7/16-24 NPTF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel pump maximum lift 6 ft (1.83 m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust outlet (pipe tapped) 1.25 inch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum exhaust back pressure 27 inches (686 mm) H Ventilation required (60 Hz) Engine (pressure cooling) 630 cfm (17.8 m

(60 Hz) Generator 160 cfm (4.53 m (1800 rpm) Combustion 29 cfm (0.8 m (50 Hz) Engine (pressure cooling) 525 cfm (14.9 m (50 Hz) Generator 133 cfm (3.8 m (1500 rpm) Combustion 25 cfm (0.7 m

BATTERY AND STARTING SYSTEM

Starting system voltage 12 volts Battery charge rate 2-5 amps. . . . . . . . . . . . .

Battery requirements:

Temperature Quantity Volts BCI Group Cranking Performance Amp.Hr.Capacity

Range Size at 0° F (-17° C) (20 hour rate)

32° F (0° C) and warmer 2 6 1 450 amps 105

0° F (-17° C) and warmer 2 6 2 560 amps 135

-25° F (-32° C) and warmer 2 6 5D 800 amps 190

O (6.7 kPa). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . . . . . .

/min). . . . . . . . . . . . . . . . . . . .

GENERATOR

Rating (AC output): 4.5 DJE (50 hz) 4.5 kW 6.0 DJE (60 hz) 6.0 kW. . . . . . . . . . . . . . . .

ENGINE

Number of cylinders (vertical in-line) 2 Displacement 70 in3 (1147 cc) . . . . . . . . . . . . . . . . . .

Cylinder bore 3.5 in. (89 mm) Piston stroke 3.625 in. (92.1 mm). . . . . . . . . . . . . . . . .

RPM 60 Hz: 1800 rpm 50 Hz: 1500 rpm. . . . . . . . . . . . . . .

Oil capacity 3 U.S. quarts plus 1/2 quart for filter. . . . . . . . .

Fuel consumption (60 Hz set) (50 Hz set)

Full load 0.64 gph (2.42 L/h) Full load 0.52 gph (1.97 L/h). . . . . . . . . . . . . .

3/4 load 0.53 gph (2.01 L/h) 3/4 load 0.42 gph (1.59 L/h). . . . . . . . . . . . . . .

1/2 load 0.43 gph (1.63 L/h) 1/2 load 0.35 gph (1.32 L/h). . . . . . . . . . . . . . .

1/4 load 0.33 gph (1.25 L/h) 1/4 load 0.33 gph (1.25 L/h). . . . . . . . . . . . . . .

ADJUSTMENT SPECIFICATIONS

Cylinder head bolt torque 37 - 40 ft-lb (50 - 54 n•m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Glow plug torque 10 - 15 ft-lb (14 - 20 n•m). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve clearances Intake: 0.010 in. (0.254 mm) Exhaust: 0.007 in. (0.178 mm). . . . . . . . . . .

Centrifugal switch breaker point gap 0.020 inch (0.508 mm). . . . . . . . . . . . . . . . . . . . .

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Page 8

Section 3. Control Description

CONTROL PANEL COMPONENTS

NOTE: Controls and instruments on the genset vary according to customer requirement.

Standard Features

• Start-Stop Switch: Starts and stops the genset lo-

cally.

• Battery Charge Rate DC Ammeter: Monitors the

battery charging current.

START-STOP

SWITCH

KNOCKOUT PLUGS FOR

OPTIONAL CONTROLS

FIELD

BREAKER

• Exciter Field Circuit Breaker: Protects the exciter

and the alternator if the voltage regulator malfunctions.

• Preheat Switch: Activates the manifold heater and

glow plugs for cold engine starting.

• Oil Pressure Gauge: Monitors engine lubricating

oil pressure.

• Fuse: Protects DC circuit against reversed battery

terminals.

PREHEAT

AMMETER

FIGURE 3-1. STANDARD CONTROL PANEL

FUSE

SWITCH

ES1972C

Optional Features (found on Housed Units)

• AC Voltmeter: Monitors output voltage.

• Voltmeter Phase Selector Switch: Selects the

output voltage phase to be measured.

• Voltage Adjust Rheostat: Adjusts output voltage

±5%.

• Running Time Meter: Registers the total genset

running time: used to time service intervals.

• Frequency Meter: Indicates the frequency (hz) of

the output voltage. This meter can be used to deter- mine engine speed (one hz equals 30 rpm).

• Warning Lights: Red warning lights indicate the

following conditions:

1. Overspeed

2. Low oil pressure

3. High engine temperature

• Reset Pushbutton: Permits restarting after a fault

condition is corrected.

• Line Circuit Breakers: Protects the generator from

line overloads.

3-1

Page 9

• Cranking Limiter: Thermally activated device lim-

its cranking time to 45 - 90 seconds, depending on ambient temperature. At the end of the cranking period, a red pushbutton pops out, which cannot be reset until one minute has elapsed.

Other Optional Control Features

(HATCO) to shut down the engine if engine temperature rises above 375° F ± 15° F (190.5° C).

• AC Control With Meters: The AC control panel has

a voltmeter, ammeter, frequency meter, phase selector switch, output voltage adjusting rheostat and resettable exciter field circuit breaker.

• Low Oil Pressure Shutdown: The engine is

equipped with a low oil pressure cutoff switch (LOPCO) to shut down the engine if oil pressure drops below 14 psi (97 kPa) ± 2 psi.

• High Air Temperature Shutdown: The engine is

equipped with a high air temperature cutoff switch

CONTROL

PANEL

TRANSFER

PUMP

OIL

FILL

PRIMARY

FUEL FILTER

SECONDARY FUEL FILTER

LIFTING

BRACKET

• AC Control - Housed Sets: The AC control panel

has a voltmeter, an ammeter for each line, a circuit breaker for each line, a frequency meter and a run- ning time meter.

VACU-FLO

AIR SCROLL

INJECTION

PUMP

O8L

FILTER

OIL

DRAIN

FIGURE 3-2. DJB GENERATOR SET

G1246

3-2

Page 10

CONTROL

PANEL

START-STOP

SWITCH

PREHEAT

SWITCH

FIELD

BREAKER

AIR CLEANER

GOVERNOR SENSITIVITY

ADJUSTMENTS

CHARGE RATE

AMMETER

FUSE

OIL FILL

TUBE

GENERATOR

PRESSURE

RUN-STOP

SWITCH

CRANKING LIMITER

RESET BUTTON

OIL

GAUGE

FUSE

FUEL

FILTERS

OIL

DRAIN

FILTER

FIGURE 3-3. DJE GENERATOR SET

START

SWITCH

OIL

SPEED

ADJUSTMENT

COOLING

AIR IN

G1246-1

PREHEAT

SWITCH

240 VAC 20 AMP

TWISTLOCK RECEPTACLE

(2)

20 AMP LINE

BREAKERS

DUPLEX 120 VAC

15 AMP OUTLET

(2)

G1246-2

FIGURE 3-4. DJE GENERATOR SET (CONTRACTOR VERSION)

3-3

Page 11

Section 4. Installation

INSTALLATION REQUIREMENTS

Generator set installations must conform to local building codes, fire ordinances, and other local, state and federal regulations.

Installation requirements include:

• Level mounting surface

• Adequate cooling air

• Adequate fresh induction air

• Discharge of circulated air

• Discharge of exhaust gases

• Electrical connections

• Fuel connections

• Accessibility for operation and servicing

• Isolation from vibration

• Minimal noise levels

For more detailed installation instructions, consult Onan Application Manual T-030, or contact an authorized Onan service representative.

Incorrect installation, service, or parts replacement can result in severe personal injury, death, and/or equipment damage. Service person- nel must be qualified to perform electrical and me- chanical component installations and service. In- stallation must comply with all state and local codes.

The left side of the set, where generator air is discharged, requires 3 inches (76 mm) clearance from the wall, so the set can rock on its mounts. There should be at least 24 inches (610 mm) clearance around all other sides for service access.

MOUNTING

A permanent genset installation must have a sturdy, level mounting base of concrete, heavy wood or structural steel. This base should be raised if possible, for easier oil changing and set operation. The set may be bolted into position.

On all installations, assemble the mounting cushions, washers and spacer bushing carefully. The spacer bush- ing prevents compression of the snubber (upper rubber cushion). Place the cushions (Figure 4-1) under the en- gine and generator mounting feet. Use cushions with a higher number (part number is shown on cushion) on the heavier generator end. Space the mounting bolts in the floor or the base with distances between hole centers as shown in Figure 4-2 for either the DJB or the DJE.

GENERATOR SET LOCATION

Provide a location for the generator set that is dry, clean, dust-free, well-ventilated, and protected from the weather.

1/16"

(1.59 mm)

The oil filter can be punctured easily by the end of the mounting bolt. For this reason, pro- vide at least 1/2-inch (12.7 mm) clearance between the oil filter and the end of the mounting bolt, to avoid puncturing the filter.

CARRIAGE

BOLT

SQUARE

NUT

LOCK

WASHER

FLAT

WASHER

SNUBBER

GENERATOR OR OIL BASE

MOUNTING

FOOT

CUSHION

MOUNTING SPACER

BUSHING

FLAT

WASHER

CS1370-1

FIGURE 4-1. MOUNTING CUSHION INSTALLATION

4-1

Page 12

11.50 IN. (292 CM.)

12.12 IN. (308 CM)

12-1/8"

(308 MM)

MOUNTING

SUPPORTS FOR

VACU-FLO UNIT

13.00 IN.

(330 CM.)

4.25 IN. (108

CM.)

7.88 IN. (220 CM.)

DJB MOUNTING BASE

4.25 IN. (108 CM.)

M1198

FIGURE 4-2. MOUNTING BASE

VENTILATION

Air circulation is needed to dissipate heat produced by the engine and generator in normal operation. Outdoor installations can rely on natural circulation, but mobile, in- door or housed installations need proper size and posi- tioned vents for required air flow. See SPECIFICATIONS for air requirements.

Vent sizes depend on variable conditions:

11-1/2" FRONT

(292 MM)

(4) 7/16 INCH

(11 MM BOLTS)

DJE MOUNTING BASE

DJE - Pressure Cooling: The pressure-cooled DJE needs an inlet vent with an unrestricted opening of at

least 3-1/2 square feet (3252 cm

) for variables. Section 2 of this manual, SPECIFICATIONS, lists the air flow re- quirement for this set. See Figure 4-4.

Air Discharge Requirements

DJE and DJB Gensets: Install separate ducts for air discharge from the engine and generator (see exception) as follows:

• Size of enclosure

• Ambient temperature

• Electrical load

• Running time

• Restrictions imposed by screens, louvers, or

filters

• Prevailing wind direction

The required volume of air must reach the unit, absorb the heat, and be discharged away from the installation.

Air Intake Requirements

DJB - Vacu-Flo® Cooling: On the DJB, the Vacu-Flo cooling inlet vent must be at least 1-1/3 sq. ft (1236 cm in area; the duct for discharged air should be at least as large as the scroll outlet. Section 2 of this manual, SPECIFICATIONS, lists the air flow requirement for this set. See Figure 4-3.

1. The engine discharge duct must be the same size as the engine outlet: 8 x 10 inches (203 x 254 mm). If a screen is used in the duct, increase the duct size in proportion to the restriction. Consider installing the screen diagonally to limit the restriction, and in- crease duct size for runs over 9 feet (2.74 m). If bends are necessary, use large radius elbows. Use a canvas section at the set to absorb vibration and noise.

2. Generator outlet ducts must be used when units are installed in compartments too small for operator to walk. Ducts are recommended for all other indoor installations. The air outlet is 5-5/8 x 3 inches (140 x 76 mm). Follow the same principles of duct design

)

and installation as used for the engine duct. Engine and generator require separate ducts.

Auxiliary fans can be used to increase airflow to units installed in small, poorly ventilated rooms. The fan size and location should be such that the air inlet to the engine

4-2

Page 13

doesn’t exceed 120° F (49° C) when running at full rated load.

Onan thermostatically controlled shutters can be used to aid warm-up after starting and keep cold air out during shutdown. When the discharged air reaches 120° F (49° C), shutters begin to open; at 140° F (62° C), the shutters completely open.

Generator set overheating can result in engine damage. To avoid this, never operate the generator set with any of the cooling system compo- nents removed.

EXHAUST

Pipe exhaust gases outside the enclosure. The exhaust outlet fits a 1-1/2 inch pipe. Locate the exhaust outlet as far as possible from the air inlet, to keep gases from reen- tering the enclosure. Use seamless flexible tubing to connect the engine exhaust to a rigid pipe extension, if used, to prevent transmission of vibration.

Inhalation of exhaust gases can result in severe personal injury or death. Modifying the ex- haust system can allow poisonous exhaust gases to escape. Use only original equipment replacement parts when servicing the exhaust system. Unauthor- ized modifications will also void the warranty and cancel the UL Listing/CSA Certification. Liability for injury or damages due to unauthorized modifica- tions becomes the responsibility of the person mak- ing the change.

Because an exhaust system is subjected to detrimental conditions such as extreme heat, infrequent operation, and light operating loads, inspect the exhaust system frequently to be sure that it remains fume-tight.

Inhalation of exhaust gas presents the hazard of severe personal injury or death. Exhaust gas can easily leak from a faulty manifold. Do not use exhaust manifold heat to warm a room or com- partment.

An approved thimble must be used (Figure 4-5) to pass exhaust pipes through walls or partitions. Build this thim- ble according to code (see National Fire Protection Asso- ciation bulletin, Volume 4, section 211 on “Standards for Chimneys, Fireplaces, and Vents”).

As the exhaust pipe length and number of bends in- creases, a larger pipe is required, to reduce excessive exhaust restriction and back pressure.

4-3

Page 14

INCOMING

SERVICE

METER

AUTOMATIC

TRANSFER

SWITCH

TO LOAD

AIR IN

FLEXIBLE

FUEL LINE

CONCRETE

BASE

MAIN FUSE

AND SWITCH

LARGE RADIUS

FLEXIBLE SECTION

ELBOW

CONDENSATION

TRAP

BATTERIES

CANVAS

SECTION

THIMBLE

HEATED ENGINE AIR

MUFFLER

DUCT TO REMOVE

FUEL

RETURN

LINE

NOTE: If revolving-field type unit is installed in smaller than approximately 384 cu. ft. (11 m generator heated air to outside.

Do not join with duct for engine heated air.

) compartment, duct

FIGURE 4-3. DJB, TYPICAL INSTALLATION

TO FUEL TANK

G1100

4-4

Page 15

LOUVERS

NEAR CEILING

INCOMING

SERVICE

MAIN FUSE

AND SWITCH

FLEXIBLE SECTION

METER

AUTOMATIC LOAD

TRANSFER CONTROL

TO LOAD

CANVAS

SECTION

THIMBLE

DUCT TO REMOVE

HEATED ENGINE AIR

AUTOMATIC

LOUVERS

MUFFLER

FLEXIBLE

FUEL LINE

FUEL

RETURN

LINE

CONCRETE

BASE

BATTERIES

TO FUEL TANK

FIGURE 4-4. DJE, TYPICAL INSTALLATION

M1880C

4-5

Page 16

SINGLE THIMBLE DIAMETER

12 INCHES (305 mm)

LARGER THAN EXHAUST LINE

HOLES IN END

(228.60 mm)

9" 9"

THROUGH WALL OR PARTITION

IF EXHAUST LINE MUST BE PITCHED

UPWARD CONSTRUCT A TRAP OF PIPE

FITTINGS AT POINT OF RISE

DRAIN CONDENSATION

TRAP PERIODICALLY

FIGURE 4-5. EXHAUST PIPING

FUEL TANK AND LINES

Fuel tanks risk explosion and fire, which can cause severe personal injury or death. Because fuel leaks create fire hazards, always use flexible tubing between the engine and the fuel sup- ply, to avoid leaks due to vibration and/or fuel line failure. Do not allow the fuel line to contact rough, sharp or hot surfaces.

Connect the fuel line to the fuel pump inlet as shown in Figure 4-6 for either the DJB or DJE generator set.

NOZZLE

INNER SLEEVE

EXHAUST LINE PASSING

AVOID SHARP BENDS

EXS1175

Use an approved flexible fuel line next to the engine. Die- sel engines require a fuel supply line and a separate fuel return line. Install the fuel supply line from the supply tank to the inverted flare male elbow mounted in the inlet of the fuel pump. The pump is threaded 7/16-24 NPTF (American Standard Internal Tapered Pipe Thread).

Install fuel return line from the 7/16-24 size opening in the overflow fitting located on injection pump (where nozzle fuel return line is also connected) to the top of the fuel supply tank. Shield the line with fire-retardant material if it passes through a combustible wall or partition.

NOZZLE

CONNECT FUEL

SUPPLY LINE HERE

RETURN

LINES

(SHADED)

CONNECT FUEL

RETURN LINE HERE

(FLEXIBLE LINE)

PUMP

FS1851C

FIGURE 4-6. FUEL LINE CONNECTIONS

CONNECT FUEL

RETURN LINE HERE

(FLEXIBLE LINE)

4-6

RETURN

LINES

(SHADED)

PUMP

FS1855C

DJE FUEL LINE CONNECTIONSDJB FUEL LINE CONNECTIONS

Page 17

Always use flexible tubing between engine and the fuel supply to avoid line failure due to vibration.

Never use galvanized or copper fuel lines, fittings or fuel tanks with diesel fuel systems. Condensation in the tank and lines combines with the sulfur in diesel fuel to produce sulfuric acid. The molecular structure of the copper or galvanized lines or tanks reacts with the acid and contaminates the fuel.

Carefully clean all fuel system components before put- ting the set into operation. Any dirt or contamination may cause major damage to the fuel injection system.

Dirt in the system can severely damage both the injection pump and the injection nozzles. Dirty fuel is one of the major causes of engine failure. Even a tiny particle of dirt in the injection system may stop the engine. Because diesel injection systems have extremely precise tolerances, make certain that fuel is kept clean.

Separate Fuel Tanks

2. If the tank is installed above the fuel pump inlet level without a supply line shutoff valve, a ruptured pump diaphragm could cause oil dilution, fuel loss, and fuel leakage to the crankcase.

3. If the maximum fuel lift must be exceeded on any installation, consult Onan Application Manual T-030 for information on installing a day tank and an elec- tric solenoid shutoff valve.

4. Use an electric or manual shutoff valve if the mini- mum fuel level in the tank is higher than the pump inlet, to provide positive fuel shutoff when the en- gine is stopped. This valve also prevents loss of fuel from possible leaks between the tank and the fuel pump.

Fuel leaks create the hazard of explo- sion and fire, which can cause severe personal in- jury or death. For these reasons, always use flexible tubing between the engine and the fuel supply, to avoid leaks due to vibration and/or fuel line failure. Make certain that the fuel system and the fuel tank lo- cation meet applicable local codes.

The fuel tank top must be lower than the fuel pump level to prevent putting a static head on the fuel pump inlet. If the fuel tank is shared with another engine, use separate fuel lines for both engines to avoid starving either one.

The following restrictions apply to separate fuel tank in- stallation:

1. The bottom of the fuel tank must not be more than 6 feet (1.8 m) below the fuel transfer pump inlet, un- less an auxiliary electric fuel pump is added. The maximum lift capacity of the transfer pump is six feet. See the Wiring Diagram for the connection.

OF FLAT FOR

INSTALLING PUMP

TO ADAPTER

SHAFT AND YOKE ASSEMBLY

SEAL

BEARINGS

TOP ENDSHAFT POSITION

EXTERNAL RETAINING

RING

PLUNGER

1 INCH (25.4 MM)

15 DEGREES

OVERLOAD FUEL PLUNGER

ADJUSTED AT FACTORY -

DO NOT CHANGE

SPRING

GUIDE

LOCK

NUT

DUST

COVER

INJECTION PUMP ADAPTER ASSEMBLY

(DJE only)

A spring and plunger assembly on the side of the pump adapter (Figure 4-7) on the DJE generator set limits the maximum power output of the engine for safe operation and permits maximum fueling during starting.

Do not change the adjustment of this de- vice unless absolutely required. The warranty may be voided if the fuel stop is intentionally altered to in- crease engine power.

ADAPTER

DOWEL PIN

HOLES (2)

PUMP MOUNTING

HOLES (4)

FIGURE 4-7. INJECTION PUMP ADAPTER ASSEMBLY

DOWEL PIN HOLE

(BRYCE ONLY)

ADAPTER MOUNTING

BOLT HOLES (4)

FS1852C

4-7

Page 18

OIL DRAIN

Extend the drain to suit the installation. The oil base has a 1/2-inch pipe size tapped hole.

Do not position the oil drain so that oil might drip onto the muffler, any exhaust components, or any other hot parts, causing a fire hazard. Fire presents the hazard of severe personal injury or death.

ELECTRICAL CONNECTIONS

The nameplate on the genset lists its electrical output rat- ing in watts, volts, and hertz. The wiring diagram, shipped with the set, depicts the electrical circuits and connections for installation.

All electrical connections should be made by an electri- cian or a qualified Onan technician, to meet the local electrical code requirements.

Electrical shock can cause severe per- sonal injury or death. Do not touch electrical wiring or components during testing. Disconnect electrical power by removing starting battery negative (-) cable before handling electrical wiring or components.

Load Wires

The control box (junction box) has knockout sections to accommodate load wires. Use flexible conduit and

LINE LOAD GEN

stranded load wires near the set, to isolate vibration. Use the correct size insulated wires for the load rating applied.

Connect each load wire to the proper generator output lead inside the control box. Insulate the bare ends of the ungrounded wires. Use the bolt provided on the control box to connect the generator ground lead or earth wire. Install a fused main switch (or circuit breaker) between the generator and the load. If a test run indicates the wrong rotation of 3-phase motors in the load circuit, switch the connections at any two of the generator termi- nals.

Electrical shock can cause severe per- sonal injury or death. Check voltage at the nearest junction box to be sure power has been discon- nected before disconnecting load wires.

An excessive electrical load can dam- age the generator windings. Divide loads equally be- tween the output leads to prevent generator damage.

Standby

If the genset is being installed for standby service, add a manual or automatic double-throw transfer switch to avoid feeding generator output into the normal power source lines, and to prevent commercial power and gen- erator output from being connected to the load at the same time. See the transfer switch installation manual for connection instructions. Also see Figure 4-8.

FIGURE 4-8. LOAD TRANSFER SWITCH

(TYPICAL FUNCTION)

BALANCING LOADS

SC1101

120/240 Volt, Single Phase: Terminal connection L0

(neutral) may be grounded, if required. For 120 volts, connect the hot load wires to either the L1 or L2 connec- tion, Figure 4-9. Connect the neutral load wire to the L0 connection. Two 120 volt circuits are thus made avail- able, with not more than 1/2 the rated capacity of the set available on either circuit. If using both circuits, be sure to balance the load between them.

4-8

Page 19

120V

FIGURE 4-9. 120/240 VOLT, SINGLE PHASE

240V

ES1804

For 240 volts, connect one load wire to the L1 connection and the second load wire to the L2 connection. Terminal connection L0 is not used for 240 volt service.

120/240 Volt, 3 Phase, 4 Wire Delta Connected Set:

The 3- phase delta connection is designed to supply 120

120V

FIGURE 4-10. 3 PHASE, DELTA CONNECTION

For 120/240 volt, 1-phase, 3-wire operation, terminals L1 and L2 are the “hot” terminals. The L0 terminal is the neutral, which can be grounded if required. For 120 volt service, connect the black load wire to either the L1 or L2 terminal. Connect the neutral (white) wire to the L0 termi- nal. Two 120 volt circuits are available.

and 240 volt, 1 phase current and 240 volt, 3 phase cur- rent (Figure 4-10). In 3-phase operation, connect the three load wires to generator terminals L1, L2 and L3 - one wire to each terminal. In 3-phase operation, the L0 terminal is not used.

240V

120V

240V

DO NOT USE THIS

CONNECTION FOR

ANY 120 VOLT LOADS

3 Phase, 4 Wire, Wye-Connected Set: The 3 phase, 4 wire connection produces line-to-neutral voltage and line-to-line voltage. The line-to-neutral voltage is the lower voltage as noted on the unit nameplate, and the line-to-line voltage is the higher nameplate voltage.

240V

200V

ES1805

Any combination of 1-phase and 3-phase loading may be used at the same time, if no terminal current exceeds the nameplate rating of the generator. If no 3-phase output is used, usable 1-phase output is 2/3 of 3 phase kVA.

120V

FIGURE 4-11. 3 PHASE, WYE CONNECTION

The terminal marked L0 may be grounded if necessary. For 1- phase loads, connect the neutral (white) load wire to the L0 terminal. Connect the black load wire to any one of the other three terminals - L1, L2 or L3. Three separate 1- phase circuits are available, with not more than 1/3 the rated capacity of the set available at any one circuit.

120V

For 3-phase loads, connect separate load wires to each of the set terminals L1, L2 and L3. Single-phase output of the higher nameplate voltage is obtained between any two 3-phase terminals as shown in Figure 4-11.

208V

120V

208V

ES1806

If using 1-phase and 3-phase current at the same time, use care to properly balance the 1 phase load, and not to exceed rated line current.

Figure 4-11 shows load connections for 120/208 voltage. Other voltages are available from either parallel wye or series wye, illustrated in Figure 4-12.

4-9

Page 20

FIGURE 4-12. GENERATOR WIRING AND CONNECTION DIAGRAMS

4-10

B200

Page 21

GROUNDING

Typical requirements for bonding and grounding are given in the National Electrical Code, 1990, Article 250.

Periodic inspection is recommended, especially after service work has been performed on equipment anywhere in the electrical system.

Generator Set Bonding and Equipment Grounding

Bonding is defined in the National Electrical Code, 1990, Article 100, as: The permanent joining of metallic parts to form an electrically conductive path which will assure electrical continuity to conduct safely any current likely to be imposed.

Bonding and equipment grounding must be done correctly for proper system operation and operator safety. Abnormal system conditions may allow ungrounded metallic parts to be ener- gized, which could result in severe personal injury or death.

Circuit and System Grounding

The design and installation of grounding systems in- volves many factors, including multiple transformers, standby generators, ground fault protection, physical lo- cations of equipment, and conductor type and size. Al- though the consulting engineer and installer are respon- sible for the design and wiring of each particular ground- ing application, system grounding must conform to na- tional and local codes.

Output Lead Markings

Leads on revolving field generators are marked T1, T2, etc. These identifying marks also appear on the wiring diagram.

SWITCHBOARD

Electrical shock can cause severe per- sonal injury or death. Use extreme caution when working on electrical circuitry. Attach and remove switchboard leads only when generator set is not op- erating. Make certain that the generator set is inop- erative by disconnecting the negative (-) battery ca- ble. Do not touch leads during operation of genera- tor set.

2. Connect the generator lead and load wires to be grounded to the ground stud on the switchboard.

3. Connect one ungrounded (hot) load wire to the unused terminal on each circuit breaker.

4. On sets that generate more than one voltage (example: 120/240), wire the voltmeter to indicate the higher voltage.

RECONNECTIBLE GENERATORS

The factory ships special-order sets with control panels especially wired for the voltage specified by the cus- tomer. Standard sets without instruments are shipped with the T1-T4 or T1-T12 output leads separated in the output box. These single-phase and broad-range gen- erators may be connected to provide any of the output voltages shown in Figure 4-12. Grounding or earthing procedures should comply with local electrical codes.

Electrical shock can cause severe per- sonal injury or death. Never remove the grounding pin from electrical equipment. Incorrect ground or no ground can cause the installation to become elec- trically “hot”. Equip the installation with adequate Ground-Fault Circuit Protection devices to meet the National Electrical Code (NFPA 70, 551- 7[C]) and to provide personal safety.

Code 3C or 53C Reconnectible Generators: The sin- gle-phase, 60- and 50-hertz generators have output leads T1, T2, T3 and T4 available to make the single phase voltage and load connections shown in Figure 4-12 at the installation site.

Code 18 or 518 Reconnectible Generators: The three-phase, broad-range, 60 and 50 hertz 12-lead gen- erators have output leads T1 through T12 available to make the single and three phase voltage load connec- tions shown in Figure 4-12.

When connecting the output leads, be sure to connect jumper W10 on the voltage regulator printed circuit board between terminal V4 (common) and V1, V2, or V3 as listed on the reconnection diagram.

Code 9x Generators: These special-order three- phase, 60 hz, 4-wire generators are rewired at the factory to provide 347/600 VAC. Output leads T1, T2, T3 and T0 are available for connection to the load wires. See con- nection diagram, Figure 4-12.

BATTERY CONNECTIONS

A optional wall-mounted switchboard contains ammeters, a voltmeter, and circuit breakers. If it is used, the following connections apply:

1. Connect one ungrounded (hot) generator lead to the unused terminal on each ammeter.

The battery is connected for negative (-) ground, Figure 4-13. Be sure all battery connections are tight.

Battery polarity must agree with the rectifier in the control box. If battery polarity must be changed, reverse the rectifier connection in the control box.

4-11

Page 22

Batteries present the hazard of explosion, which can result in severe personal injury. Disconnecting battery cables from the battery while the generator set is cranking or running causes arcing. For this reason, do not disconnect battery cables from the battery while the generator set is cranking or running. To minimize arcing, always disconnect the negative (-) cable first, and connect it last.

STARTING MOTOR

SOLENOID

BATTERY POSITIVE

STARTING MOTOR

BATTERY NEGATIVE

CABLE SIZE

mm 6.5 7.3 8.3 9.3 10.5 11.6

INCH .258 .289 .325 .365 .410 .460

WIRE SIZE

LOOP 4 ft 5 ft 7 ft 9 ft 11 ft 14 ft

2 1 0 00 000 0000

1.24 m 1.55 m 2.17 m 2.79 m 3.41 m 4.34 m

FIGURE 4-13. BATTERY CONNECTIONS AND

CABLE DIMENSIONS

Reversed battery polarity can damage or destroy the generator within 3 minutes if stopped, or within 5 seconds if running. With reversed polar- ity, alternator windings will be damaged almost in- stantly if the battery charging circuit is shorted be- tween resistor R21 and the B1 end of the charging winding. Make certain that battery polarity is cor- rect, to avoid damaging or destroying the system.

See the Specifications section of this manual for the 12 volt battery minimum requirements. Connect battery positive (+) to starter engaging solenoid terminal post, Figure 4-13. Connect battery negative (-) to a solid ground connection on the engine.

OPTIONAL ALARM

The GND terminal on the remote control terminal block is

12 V BATTERY

ES1962

intended for a customer-supplied alarm at a remote loca- tion, to warn of emergency shutdown. Refer to the Wiring Diagram for proper alarm connections.

REMOTE START-STOP SWITCH (Optional)

Use 2 wires to connect the SPST remote start-stop switch to the terminal block marked B+ and to the remote in the control box, using the wire sizes listed in Figure 4-14.

Incorrect connections can damage the control, the remote switch, and the interconnecting wiring. Ensure that the leads from the remote switch connect with the corresponding terminals on the generator set.

4-12

Page 23

WIRE SIZE DISTANCE

#18 (1.02 mm) to 65 ft. (20 m) #16 (1.29 mm) to 100 ft (31 m) #14 (1.63 mm) to 150 ft. (47 m) #12 (2.05 mm) to 280 ft. (87 m)

START

STOP

PREHEAT

MOMENTARY

CONTACT

SWITCHES

FIGURE 4-14. REMOTE CONTROL

REMOTE CONTROL

TERMINAL BLOCK

AT GENERATOR

B+

ES1970C

4-13

Page 24

Section 5. Operation

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, an odorless and colorless gas. Car- bon monoxide is poisonous and can cause unconsciousness and death. Symp- toms of carbon monoxide poisoning can include:

• Dizziness • Throbbing in Temples

• Nausea • Muscular Twitching

• Headache • Vomiting

• Weakness and Sleepiness • 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 atten- tion. Shut down the unit and do not operate until it has been inspected and re- paired.

Protection against carbon monoxide inhalation includes proper installation and regular, frequent visual and audible inspections of the complete exhaust system.

PRE-STARTING

Preparation for initial and subsequent starts includes careful checks of the oil, fuel, cooling, and electrical sys- tems. Close the cylinder air housing door with all air shrouds in place.

Before the generator set is activated, check all compo- nents for mechanical integrity. If an abnormal condition, defective part, or operating difficulty is detected, repair or service the genset as required. Keep the generator set free of dust, dirt, and spilled oil or fuel.

Accidental starting of the generator set can cause severe personal injury or death. Make cer- tain the generator set is stopped and disconnect the starting battery cables (negative [-] cable first) be- fore inspecting the generator set.

Oil Recommendations

The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals are criti- cal factors in maintaining engine performance and durability.

Use SAE 30 oil that meets the American Petroleum Institute (API) Classification of CE/SF. CD/SF oil may be used in areas where CE/SF oil is not available. CE and

CD oils are designed for high temperature, severe duty service.

A maximum sulfated ash content of 1.85 mass % is rec- ommended to prevent guttering and valve burning.

The use of a multi-viscosity lubricating oil has been found to improve oil consumption control and improve engine cranking in cold temperatures while maintaining lubrica- tion at high operating temperatures. While 15W-40 oil is recommended for most climates, refer to the accompa- nying table for oil viscosity recommendations for extreme climates.

Limited use of low viscosity oils, such as 10W-30 may be used for easier starting and pro- viding sufficient oil flow at ambient temperatures be- low -5° C (23° F). However, continuous use of low vis- cosity oils can decrease engine life due to wear. Re- fer to the accompanying chart.

If an engine is operated in ambient temperatures consis- tently below -23° C (-10° F) and there are no provisions to keep the engine warm when it is not in operation, use a synthetic CE/SF or CD/SF engine oil with adequate low temperature properties such as 5W-20 or 5W-30.

The use of a synthetic base oil does not justify extended oil change intervals. Extended oil change intervals can decrease engine life due to factors such as corrosion, deposits and wear.

5-1

Page 25

In extremely dusty or dirty conditions, oil should be changed more frequently. When adding oil between changes, use the same brand as already in the engine. Various brands of oil may not be compatible when mixed.

TABLE 5-1. SAE OIL VISCOSITY RECOMMENDATIONS

Refer to the Maintenance section of this manual for oil change interval and procedures. Always change the oil filter when changing the oil.

ALWAYS RETURN PRIMER LEVER TO LOWEST POSITION

DJB FUEL SYSTEM BLEEDING

WORK TRANSFER PUMP

PRIMING LEVER UNTIL

FUEL FLOWS FROM

RETURN LINE FITTING ON

INJECTION PUMP

INJECTION

PUMP RETURN

LINE FITTING

FS1777

FIGURE 5-2. FUEL SYSTEM

RETURN LINE

EXS-1147-1

WORK TRANSFER PUMP PRIMING LEVER UNTIL FUEL FLOWS FROM RETURN LINE

OF INJECTION PUMP

DJE FUEL SYSTEM BLEEDING

FS1854C

Recommended Fuel

Use ASTM 2-D or 1-D fuel, with a minimum Cetane number of 45*. Number 2 diesel fuel is usually most economical; however, use ASTM 1-D fuel during the following conditions:

1. When ambient temperatures are below 32° F (0° C)

2. During long periods of light engine load or no load

NOTE: Fuels with Cetane numbers higher than 45 may be necessary in higher altitudes or in extremely low ambient temperatures, to prevent misfires.

Use fuel with a low sulfur content and a pour point (ability to filter) of at least 10°F (6°C) below the lowest expected ambient temperature. Keep fuel clean and protected

5-2

Page 26

from adverse weather. Leave room for fuel expansion when filling the fuel tank.

during cranking indicates that no fuel is reaching the engine.

Dirt in the system can severely damage both the injection pump and the injection nozzles. Because diesel injection systems have extremely precise tolerances, make certain that fuel is kept clean.

Bleeding Fuel System

Bleed air from fuel system as follows: Disconnect the fuel return line (Figure 5-2). Operate the hand priming lever on the fuel transfer pump until the fuel flowing from the fuel return line is free of air bubbles. Then reconnect the fuel return line. Cranking the engine should expel trapped air from the injection pump.

If the camshaft’s pump lobe is up, crank the engine one revolution to permit hand priming. When finished, return priming lever inward (disengaged position) to permit nor- mal pump operation.

PRE-HEATING AND STARTING

Preheat the engine for 60 seconds when the ambient temperature is 55°F (13°C) or lower. Preheat the engine for 30 seconds in temperatures above 55°F (13°C).

6. In extreme cold (below 32°F or 0°C) it may be nec- essary to maintain preheating for two minutes after the engine starts, to obtain firing or smooth out cylinders, especially at no load or light loads.

NOTE: When remotely starting the set, the switch on the set con- trol must be in its remote position.

Preheating the engine longer than one minute in moderate ambient temperatures before cranking the engine can destroy the manifold heater and glow plugs, because there is no incoming air flow to cool them. For this reason, do not exceed the one minute preheat periods (unless ambient tem- perature is below 0°F), to prevent heater burnout and conserve the battery.

NOTE: Continuous operation of the preheaters during cranking in cold weather helps preheat the incoming combustion air, to pre- vent misfires as the engine starts running.

When the engine reaches operating speed, the centrifu- gal switch and the start-disconnect relay automatically stop cranking. If the engine fails to start in 45 to 120 sec- onds, the cranking limiter trips and stops cranking. If this occurs, wait one minute before resetting the cranking limiter and trying to restart the engine.

Do not use ether as a cold weather start- ing aid. The heat from the glow plugs or manifold heater may cause a sudden ignition of the ether va- por. This can result in personal injury and damage to the engine.

To preheat the engine:

1. Engage the preheat switch for one minute. On con- tractor models, turn OFF-RUN switch to RUN.

2. Release the preheat switch and engage the start switch. On contractor models, continue to hold PREHEAT switch until engine comes up to speed. On all other models, hold START switch to START until engine comes up to speed. (This will maintain heater operation until START switch is disen- gaged.)

3. Release the start switch after the engine reaches speed.

4. Check the oil pressure gauge: it should read at least 20 psi (138 kPa).

NOTE: Depress the preheat switch for one minute, then release it and push the start switch.

If the control has an emergency relay reset button, per- form reset only after a shutdown occurs due to low oil pressure or high water temperature. Make certain to find the cause of the failure before restarting the engine.

Overvoltage will destroy the glow plugs and air heater in 2 to 3 seconds. If extra power is needed to start the set, connect an additional 12 volt battery in parallel to the starting battery. Do not ap- ply overvoltage to the starting circuit at any time.

STOPPING

1. Push the start-stop switch to the stop position.

2. If the stop circuit fails, push governor arm down to shut off fuel injection pump.

AUTOMATIC STARTING AND STOPPING

An optional automatic demand control may be used for starting and stopping, but it must provide engine preheat- ing.

NOTE: the pressure-relief valve is not adjustable.

5. If the engine fails to begin firing after 20 seconds of cranking, return to the preheat procedure of step 1, then repeat step 2. Absence of blue exhaust smoke

The automatic control has a time delay relay to preheat glow plugs and the manifold heater for about 20 seconds before cranking occurs. The time delay relay prevents immediate engagement of the starter in case a load is reapplied before the engine comes to a complete stop.

5-3

Page 27

APPLYING LOAD

EXERCISING UNIT

Allow the set to warm up before connecting a heavy load. Continuous generator overloading may cause high operating temperatures that can damage the windings. Keep the load within the nameplate value for normal operation. Carbon deposits may form on the exhaust system during operation at light loads; apply full load occasionally be- fore shutdown to prevent excessive carbon accumula- tions. When possible, connect the load in small incre- ments, instead of fully loading the genset at once.

EXHAUST SYSTEM INSPECTION

Make regular inspections of the exhaust system. If you notice a change in the sound or appearance of the ex- haust system, shut the unit down immediately and have it inspected by your Onan dealer or distributor.

Exhaust gas presents the hazard of se- vere personal injury or death. Inspect the exhaust system audibly and visually each day. With the gen- erator set running, momentarily open the access cover to inspect the muffler. Have any leaks repaired immediately.

BREAK-IN PROCEDURE

Continuous generator set overloading can cause high operating temperatures that could damage the generator windings. Keep the load within the nameplate rating.

Observe the following schedule for genset break-in:

1. One half hour at 1/2 load.

2. One half hour at 3/4 load.

3. Full load.

Do not run the generator set continuously under one half load during the first few hundred hours of operation. This usually results in poor piston ring seating, causing higher-than-normal oil consumption and blowby.

Drain and replace the crankcase oil after the first 50 hours of operation. Do this while the engine is still hot.

SAFETY DEVICES

In case of dangerously low oil pressure (below 14 psi [97 kPa]), the cutoff switch (LOPCO) stops the unit. After an emergency stop, investigate and correct its cause. Press the reset button on the control panel before restarting.

Infrequent use of the generator set can cause it to deteriorate. The following can occur:

• Condensation in the fuel and lubrication system, causing contamination and/or corrosion

• Loss of protective oil film on moving engine parts

• Loss of engine fuel prime due to drain-back and/or

evaporation

• Battery discharge due to internal and external cur- rent leakage

• Breakdown of generator insulation due to water ab- sorption

Proper exercising does the following:

• Elevates engine oil temperature to at least 180°F (82.2°C)

• Evaporates water from engine lubrication system

• Reestablishes a protective oil film on engine parts

• Recharges battery to full normal potential

• Brings generator to normal operating temperature

through load application

The generator set should be exercised at least once each week: the engine oil temperature should be held at 180°F (82.2°C) for at least 30 minutes during this exercise.

To exercise the generator set, do the following:

1. Perform all required maintenance checks, start the unit, and apply a load by creating a simulated power failure*. This exercises the control and switchgear systems.

2. Apply at least 50 percent load, using the thermos- tatic shutters if needed, to heat the engine and gen- erator, as described above.

3. Exercise the unit long enough to provide at least 30 minutes running time at normal operating tempera- tures. This requires at least 60 minutes total running time.

4. Shut the unit down by simulating the return of nor- mal power*. Run the set for approximately 10 minutes with no load to allow the engine to cool down.

Hot oil can cause severe personal injury. Do not check the oil level while the generator set is running; wait until the generator set is cool before investigating.

* This applies to a standby genset only. Other units

should be started and loaded by control and load application systems normally associated with operation of the unit.

5-4

Page 28

Improper exercising may cause more damage than no exercising at all. Significant amounts of water and raw fuel will remain in the lubrication oil if the unit is run at a low operating temperature. Also, operating the engine at no load or at low temperatures causes carbon buildup and exhaust system fouling. Continued operation in this manner may cause starting failure and/or engine damage. Exercising a generator set without exercising its as- sociated controls and switchgear does not test the operation of the controls and switchgear. If the con- trol systems are not fully functional, the system may fail to provide power when required.

After each exercise period, refill the fuel tank and check the engine for leaks and overall condition. Locate the cause of any leaks and correct.

ENGINE RATINGS

Ratings apply to altitudes up to 1000 feet (305 m), gen- sets using standard cooling, normal ambient tempera- tures and with No. 2 Diesel fuel. Consult the nearest authorized Onan service center for operating character- istics under other conditions.

DUST AND DIRT

1. Keep the generator set and the cooling system clean.

2. Service the air cleaner as frequently as necessary.

3. Change the crankcase oil every 100 operating hours.

4. Keep oil and fuel in dust-tight containers.

5. Keep governor linkage clean.

HIGH ALTITUDE

Maximum power is reduced approximately 4 percent for each 1000 feet (305 m) altitude above sea level, after the first 1000 feet (305 m).

OUT-OF-SERVICE PROTECTION

The lubricating qualities of diesel fuel should protect a diesel engine for at least 30 days when the unit is not in service. To protect a set that will be out of service for more than 30 days, proceed as follows:

HIGH/LOW OPERATING TEMPERATURES

The generator set has been designed to operate satis- factorily in both high (above 100° F) and low (below 0° F) temperatures. Use the oil recommended in the PRE- START section for the expected temperature conditions.

High Operating Temperatures

1. See that nothing obstructs air flow to and from the set.

2. Keep cooling fins clean. Cylinder air housings should be properly installed and undamaged.

Low Operating Temperatures

1. Use correct viscosity oil for temperature conditions. Change oil only when engine is warm. If an unex- pected temperature drop causes an emergency, move the set to a warm location or apply heated air (never use open flame) externally until oil flows freely.

2. Use fresh fuel. Protect against moisture condensa- tion.

3. Keep fuel system clean, and batteries in a well charged condition.

1. Run the set under at least 50 percent load, until it is thoroughly warmed up.

2. Shut down the engine.

3. Disconnect the starting batteries and follow stan- dard battery storage procedures.

Freezing temperatures may se- verely damage the starting batteries. When the batteries are in storage, be certain to maintain their liquid level. Use a trickle charger to main- tain the correct specific gravity.

4. Drain the oil from the crankcase while the engine is warm. Refill it with clean oil, and attach a tag listing the type of oil used.

5. Remove the flexible section of the exhaust line. (The exhaust should have a rain cap to prevent the entrance of moisture and dirt. If not, the exhaust can be plugged.)

6. Service the air cleaner.

7. Remove the glow plugs from the cylinders. Pour 1 ounce (30 ml) of rust inhibitor (or SAE #10 oil) into each cylinder. Crank the engine over several times. Reinstall the glow plugs.

4. Partially restrict cool air flow but use care to avoid overheating.

5. Use additional preheating during cold starts.

Do not exceed one ounce oil per cylinder. excess oil may fill the combustion chamber and prevent the engine from cranking, due to hydraulic lock.

5-5

Page 29

8. Check the fuel filters for the presence of water, as shown in the Periodic Maintenance section.

9. Clean the throttle and governor linkage. Protect them by wrapping with a clean cloth.

10. Clean and wipe the entire unit. Coat parts susceptible to rust with a light coat of oil or grease.

11. Provide a suitable cover for the entire unit after it cools down.

RETURNING THE SET TO OPERATION

1. Remove the protective cover from the unit. Wipe off dust and dirt.

2. Check that fuel lines and injectors are secure and properly torqued without air or fuel leaks.

3. Check the tag stating the oil type and weight. If it is not correct, drain oil from the engine, and refill with the correct oil. Be sure that it is up to “FULL” mark on dipstick.

4. Remove the material used to plug the exhaust outlet and reconnect the exhaust line. Check the com- plete exhaust system for tight connections. Note the condition of the muffler, exhaust line, etc., and repair as necessary.

After the engine has started, excessive blue smoke will be exhausted until the rust inhibitor or oil has burned away.

Exhaust gases contain carbon monoxide, which may cause severe personal in- jury or death. Before operating the generator set, make certain the exhaust line is connected correctly, is fit for operation, and does not leak.

5. Check the entire generator set for fuel or oil leaks. Correct as required.

6. Check the wiring system for worn wires, loose con- nections, etc. Repair as required.

7. Install the fully-charged batteries, and connect them to the generator set. Observe correct polarity. Con- nect the ground cable last.

Explosive gases are emitted from batteries when they are being charged. Ignition of these gases can cause severe personal in- jury. Do not smoke or allow flame, sparks or arc- ing equipment in the vicinity while servicing batteries.

8. Verify that no loads are connected to the generator.

9. Start the engine, and observe the oil pressure gauge and charge rate ammeter. After start, apply load to at least 50 percent of rated capacity.

5-6

Page 30

Section 6. Adjustments

Inadvertently starting the engine may result in damage to the generator set or serious personal injury. For this reason, disconnect the batter- ies, negative (-) cable first, before beginning any ad- justment or maintenance work on the engine, gen- erator, control panel, automatic transfer switch or associated wiring.

CENTRIFUGAL SWITCH

The start-disconnect centrifugal switch (Figure 6-1) is lo-

cated on the side of the engine, above the oil filter. The switch opens when the engine stops, and closes when engine speed reaches 900 rpm. If necessary, loosen the stationary contact and adjust the point gap to 0.020 inch (51 mm). Replace burned or faulty points.

High voltage, which can cause severe personal injury or death, is present at the breaker point gap. For this reason, disconnect the battery cable, negative [-] terminal first, before setting the breaker point gap.

CENTRIFUGAL SWITCH

BREAKER POINTS

SET GAP AT 0.020 INCH

(51 mm)

FIGURE 6-1. CENTRIFUGAL SWITCH ADJUSTMENT

GOVERNOR

The governor controls engine speed. On a 4 pole gen- erator, engine speed equals frequency multiplied by 30. Thus 1800 rpm generates 60 hertz. Preferred engine speed does not vary more than 3 hertz from no-load to full-load operation. Be sure that the throttle, linkage, and governor mechanism operate smoothly.

Speed Adjustment

To change the governor speed, change the spring ten- sion by turning the governor spring nut, Figure 6-1. Turn the nut clockwise (more spring tension) to increase rpm, or counterclockwise to reduce governed speed. Use a

ES1808

stroboscope or a frequency meter to make this adjust- ment.

Sensitivity Adjustment

To adjust governor sensitivity (no-load to full-load speed droop), turn the sensitivity adjusting ratchet. On city water-cooled units, turning the ratchet counterclockwise provides more sensitivity (less speed drop when full load is applied), and turning it clockwise provides less sensi- tivity (more speed drop).

If the governor is too sensitive, a rapid hunting condition occurs (alternate increasing and decreasing speed). Ad- just the governor for maximum sensitivity without hunt- ing. After making the sensitivity adjustment, readjust the speed.

6-1

Page 31

SPEED

ADJUSTING

NUT

GOVERNOR

SPRING STUD

(SENSITIVITY

ADJUSTMENT)

TURN TO

INCREASE RPM

(Hold spring stud in

position)

TURN FOR

MINIMUM SPEED

DROP, THEN

ADJUST SPEED

CUT

CHARGE RATE ADJUSTMENT

The adjustable resistor slide tap (Figure 6-3) in the charging circuit is set to produce a 2 ampere charging rate. This resistor is found in the generator air outlet. For applications requiring frequent starts, check the battery specific gravity periodically. If necessary, increase the charging rate slightly (move the slide tap up). Adjust this slide tap only when the engine is stopped.

GOVERNOR

ARM

SENSITIVITY

ADJUSTING

RATCHET

DECREASE

SENSITIVITY

FIGURE 6-2. ADJUSTING GOVERNOR

COOLING AIR OUTLET

CHARGING RESISTOR

GOVERNOR

SPRING

INCREASE

SENSITIVITY

GOVERNOR

STUD

SPEED

ADJUSTING

NUT

DECREASE

SPEED

INCREASE

SPEED

FS1778

ES1971C

FIGURE 6-3. CHARGING RESISTOR

Batteries present the hazard of explo- sion, which can result in severe personal injury. Be- cause batteries produce explosive gas, do not smoke or allow any flame, sparks, or arc-producing devices in the battery area.

Avoid overcharging the battery. Make small increments of change until the proper rate has been determined to keep the battery charged.

VALVE CLEARANCE ADJUSTMENTS

Check the valve clearance when the engine is at room temperature, about 70°F (21°C).

Incorrect valve clearance adjustment can lead to irrevocable damage to the generator set. Make certain that only qualified personnel perform this adjustment.

1. Turn the flywheel until the cylinder which is to have its valve adjusted is on its compression stroke. On engines without a hand crank, use a socket wrench on the flywheel hex head screw.

To determine if the cylinder is in its compression stroke, observe the push rods as the engine is rotated in a clockwise direction. The exhaust valve push rod will be in its lowest position, and the intake valve push rod will be moving downward. As the

6-2

Page 32

piston reaches top dead center, the flywheel timing mark should be aligned with the timing pointer, and the valve push rods should be stationary.

2. Turn the flywheel an additional 10 to 45 degrees clockwise (estimated). When the piston is in this position, it is in its power stroke, with both valves com-

ADJUST VALVE

CLEARANCE HERE

VALVE SPRING

RETAINER

VALVE

SPRING

OIL SEAL

pletely closed.

3. Check cylinder head-bolt torque prior to valve clearance adjustment. Torque values are listed in Section 2, Specifications. Adjust valve clearance with the locknut which secures the rocker arm to the cylinder head (see Figure 6-4). Loosen this locknut to increase clearance: tighten it to reduce clearance.

ROCKER

ARM

FIGURE 6-4. VALVE CLEARANCE ADJUSTMENTS

4. Using a feeler gauge, check the clearance between the rocker arm and the valve (see Figure 6-5). In- crease or decrease the clearance until the proper

FIGURE 6-5. CHECK VALVE CLEARANCE

INTAKE

VALVE

ONLY

VALVE

SEAT

EXHAUST VALVES

VALVE

PUSH ROD

VT1044

gap is established. Valve clearances are listed in the Specifications section.

PCV VALVE

INTAKE

VALVES

VT1045

6-3

Page 33

Section 7. General Maintenance

Follow a regular schedule of inspection and servicing, based on operating hours. Keep an accurate record of maintenance, service, and operating time. Use the run- ning time meter (optional) to monitor operating hours. Follow the service schedule listed in the Periodic Mainte- nance Schedule on page 8-1.

Many maintenance procedures present hazards which can result in severe personal injury or death. Only qualified service personnel with knowl- edge of fuels, electricity, and machinery hazards should perform service procedures. Review the safety precautions on the inside cover page of this manual.

PERIODIC CHECKS

1. Check all fuel and oil lines for possible leakage.

2. Inspect exhaust lines and mufflers for possible leak- age and cracks.

3. Periodically drain moisture from condensation traps.

4. Inspect the cooling system. Be sure the cooling fins are clean.

5. Inspect electrical wires and connections to see they are secure and have no fray damage.

If the generator requires major repair or servicing, contact an authorized Onan service center.

BATTERIES

Check the condition of the starting batteries at least every two weeks. Make certain that connections are clean and tight. A light coating of non-conductive grease will retard corrosion at terminals. Add distilled water t o keep the electrolyte at the proper level above the plates. Check the specific gravity; recharge if below 1.260 at 77°F (25°C).

Batteries present the hazard of explo- sion, which can result in severe personal injury. Dis- connecting battery cables from the battery while the generator set is cranking or running causes arcing. For this reason, do not disconnect battery cables from the battery while the generator set is cranking or running. To avoid excessive arcing, always dis- connect the negative (-) cable first, and connect it last.

Discharged batteries are subject to se- vere damage if exposed to freezing temperatures. Store all batteries in a fully charged condition, and maintain their charge during storage.

FUEL FILTERS

Every 100 hours, open the drains on the bottom of the fuel filter assembly (Figure 7-1) and allow any water to escape. The drain plug on the fuel filter can tolerate only a limited amount of torque. Use two wrenches in combi- nation for breaking the plug loose and for final tightening.

Inadvertently starting the engine may result in damage to the generator set or serious per- sonal injury. For this reason, disconnect the batter- ies, negative (-) cable first, before beginning any maintenance work on the engine, generator, control panel, automatic transfer switch or associated wir- ing.

CONNECTOR

(FROM FUEL

TRANSFER

PUMP)

PRIMARY

FILTER

DRAIN

FIGURE 7-1. DUAL FUEL FILTERS

Fuel presents the hazard of fire or ex- plosion which can cause severe personal injury or death. Do not permit any flame, spark, pilot light, cigarette, arc-producing equipment or other ignition source near the fuel system. Keep an ABC type fire extinguisher nearby.

ELBOW (TO

INJECTION

PUMP)

SECONDARY

FILTER

DRAIN

FS1113

7-1

Page 34

Every 600 hours, change the primary fuel filter by removing the washer and capscrew on top of the fuel filter body. Every 3000 hours, change the secondary fuel filter in the same manner as the primary fuel filter.

Fuel presents the hazard of fire or explosion that can cause severe personal injury or death. Do not work on the fuel system when the gen- erator set is hot. Clean fuel spills and allow vapor to evacuate prior to starting the generator set.

GOVERNOR LINKAGE

Every 100 hours, carefully pull the neoprene governor ball joints apart and clean them. Do not lubricate these joints. See Figure 7-2.

CLEAN BALL JOINT

FIGURE 7-2. GOVERNOR BALL JOINT

Some solvents can damage the neo- prene governor ball joints. Read the manufacturer’s recommendations before using any lubricants or solvents near the ball joints.

Fumes from this cleaner may present the hazard of fire or explosion, which can cause se- vere personal injury or death. Do not allow any spark, flame, pilot light, lit cigarette, arc-producing equipment or other ignition source near the genera- tor set when performing this procedure. Keep a fire extinguisher rated ABC near the work area.

FS1114

CRANKCASE BREATHER TUBE

To clean the crankcase breather tube, remove both rocker covers, as shown in Figure 7-3. The breather tube itself is installed with a sealant on the threads to prevent oil leakage into the intake manifold: it should NOT be re- moved. A small wire, nail or drill bit inserted through from the top can be used to clean out the breather hole. The breather hole seldom needs cleaning: a 500 hour interval coincides with the valve lash adjustments, because the rocker box covers must be removed at that time.

7-2

Page 35

FIGURE 7-3. CLEANING BREATHER

CRANKCASE

BREATHER

TUBE

CLEAN

CRANKCASE

BREATHER PIPE EVERY 500 HOURS

C1014

CRANKCASE BREATHER

After every 200 hours of operation, remove hose clamp, breather hose, breather cap clamp and insulator halves

BREATHER

HOSE

SCREEN

HOSE CLAMP

CAP AND VALVE

O-RING

FILTER

BREATHER

TUBE

FIGURE 7-4. CRANKCASE BREATHER

OIL

BAFFLE

ASSEMBLY

LS1206C

SCREEN

RETAINER

CLAMP

to release breather cap and valve assembly, Figure 7-4. Wash cap, valve assembly and baffle in suitable solvent. Dry and reinstall.

7-3

Page 36

FUEL PUMP SEDIMENT BOWL

Fuel presents the hazard of fire or explosion which can cause severe personal injury or death. Do not permit any flame, spark, pilot light, cigarette, arc-producing equipment or other ignition source near the fuel system. Keep an ABC type fire extinguisher nearby.

FUEL PUMP AND FILTER

BODY

FILTER

GASKET

BOWL

Every 100 hours, remove the sediment bowl from the fuel transfer pump and filter body (Figure 7-5). Clean out any water or particulate present in the bowl and filter. When re-installing the sediment bowl, make sure the filter and gasket are in place.

FIGURE 7-5. FUEL PUMP SEDIMENT BOWL

AIR CLEANERS

After every 50 hours of operation, remove and clean the filter element (Figure 7-6). After washing the element in

ELEMENT

RETAINER

M1770

FIGURE 7-6. POLYURETHANE FOAM AIR CLEANER

CONTRACTOR MODEL AIR CLEANER

1. Remove pre-cleaner and wash out dirt. Dry and reinstall.

2. Loosen clamp and remove end cover.

FS1115

solvent, dip the element in engine oil and squeeze it as dry as possible.

3. Remove thumbscrew and take out element. Wash element in detergent and water (use new element after 6 washings). Dry and reinstall.

4. Remove air cleaner baffle from cover, wash out dirt, and reinstall in cover.

7-4

5. Install cover with ”TOP” up and tighten clamp.

Page 37

COVER

DUST CUP

(PRE-CLEANER)

THUMBSCREW

BAFFLE

ELEMENT

CLAMP

FIGURE 7-7. DJE CONTRACTOR MODEL AIR CLEANER

FS1853C

7-5

Page 38

OPTIONAL OIL BATH AIR CLEANER

1. Loosen the bottom clamp, remove the cleaner base and clean the part (Figure 7-8).

KEEP OIL AT

THIS LEVEL

FIGURE 7-8. OIL BATH AIR CLEANER

2. Refill the base to the oil level mark with fresh oil of the same weight as used in the engine.

M1771

OIL FILTER CHANGE

Place the pan under the oil filter and remove the filter by turning it counterclockwise. Clean the filter mounting area. Oil filter gasket with clean oil. To install the new fil- ter, turn the filter on clockwise until the gasket touches the mounting base, then tighten 1/2 turn.

Hot oil and a hot oil filter may cause se- vere burns to the skin. Wear goggles, apron and gloves when replacing the oil filter.

OIL CHANGE

Stop the engine and drain the crankcase oil while the en- gine is still hot. Place a pan under the drain outlet and remove the oil drain plug or open the oil drain valve. After the oil is completely drained, replace the drain plug or close the drain valve. Refill with oil of the correct API des- ignation and SAE viscosity grade for the temperature conditions (refer to Operation section).

Hot oil may cause severe burns. Wear goggles, apron and rubber gloves, and use extreme care when changing the oil.

Check the oil level indicator after every 8 hours of opera- tion, and maintain the oil level at the full mark (Figure 7-9). The oil should be changed after every 100 hours of operation. Refer to the Specifications section for crank- case and filter capacity.

Hot oil may cause severe burns by blowing out from the oil fill tube of a running genera- tor set. Do not check the oil level while the generator set is operating.

7-6

Page 39

ALWAYS REPLACE CAP

TIGHTLY OR OIL

LEAKAGE MAY OCCUR

CAP AND OIL LEVEL

INDICATOR

KEEP CRANKCASE

OIL AT THIS LEVEL

NEVER OPERATE

ENGINE WITH OIL

BELOW THIS LEVEL

LS1181

OIL FILL

TUBE

FULL

LOW

FIGURE 7-9. OIL LEVEL INDICATOR

7-7

Page 40

Section 8. Periodic Maintenance

Schedule

Regularly scheduled maintenance means lower operat- ing costs and longer service life for the generator set. The following schedule may be used as a guide. How- ever, actual operating conditions should determine the maintenance schedule. In exceptionally dusty or dirty conditions, certain service periods may have to be re- duced. Check the condition of the crankcase oil, filters, etc., frequently, until the proper service time periods are established.

If any abnormalities in operation, unusual noises from engine or accessories, loss of power, overheating, etc. occur, contact the nearest authorized Onan dealer.

Exhaust gas presents the hazard of se- vere personal injury or death. Inspect the exhaust system audibly and visually each day, or each time the generator is started (whichever is sooner). With the generator set running, momentarily open the ac- cess cover to inspect the muffler. Shut down the generator set and have any leaks repaired immedi- ately.

Failure to disconnect the generator set battery could result in damage to equipment or seri- ous personal injury in the event of inadvertent start- ing. Before beginning any maintenance work on the engine, generator, control panel, automatic transfer switch or associated wiring, disconnect the battery, negative (-) cable first.

Many troubleshooting and mainte- nance procedures present hazards which can result in severe personal injury or death. Only qualified service personnel with knowledge of fuels, electric- ity, and machinery hazards should perform service procedures. Review safety precautions on inside cover page before attempting these maintenance procedures.

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HOURS OF OPERATION MAINTENANCE TASK

8 • Inspect exhaust system

• Inspect generator set

• Check fuel supply; see Note 1

• Check oil level

50 (more often in • See Note 3. dusty conditions) • Check air cleaner

100 • Clean governor linkage

• Change crankcase oil (or annually)

• Clean sediment bowl and

filter on fuel transfer pump. See Note 1.

• Replace oil filter

• Check battery condition

500 • Check start-disconnect circuit

• Check valve clearances

600 • Change primary fuel filter

2000 • Grind valves (if required)

• Clean holes in rocker box oil line

• Check nozzle spray pattern;

see Note 2

• Clean generator

3000 • Change secondary fuel filter

5000 • General overhaul (if required)

See Note 3.

1. Water or foreign material in fuel can ruin the injection system. If daily inspection shows water or excessive dirt in sediment bowl, fuel handling and storing facilities should be checked and situation corrected. Primary and secondary fuel filters can be replaced following correction of fuel contamination problem.

2. This service must be conducted by trained diesel injection equipment personnel with suitable test facilities. Omit this service until these conditions can be met.

3. Tighten head bolts and adjust valve clearance after first 50 hours on new and over- hauled engines, and then adjust valve clearance each 500 hours thereafter.

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