Onan RDJC Operator's Manual

»

Onon Operator's

RDJC

Manual

GENERATOR

SET

Printed U.S.A.

974-0127

8-94

Table of Contents

SECTION TITLE PAGE

SAFETY

1 INTRODUCTION 1-1

About This Manual 1-1
Safety Considerations 1-1
How To Obtain Service 1-1

2 SPECIFICATIONS

3 INSTALLATION 3-1

General 3-1

Location 3-1
Mounting 3-2

Ventilation 3-3

Radiator Cooling 3-3

City Water Cooling (Opitional) 3-3

Exhaust 3-4
Fuel Tank And Unes 3-5

Oil Drain 3-6

4 ELECTRICAL PREPARATION 4-1

General 4-1

Transfer Switch 4-2

Generator Voltage Connections 4-3
Load Connection 4-4

DC Wiring 4-6

Battery Connections 4-6

5 CONTROL DESCRIPTION 5-1

PRECAUTIONS

2-1

iii, iv

General 5-1

DC Controls , 5-2

AC Controls.. 5-4

SECTION

TITLE PAGE

6 OPERATION 6-1

General S'

1

Prestart Checks 6-2
Starting 6-3

Running 6-5
Stopping 6-6
Break-In 6-7
No-Load Operation 6-7

Exercising Period • • 6-7
High Temperatures 6-8

Low Temperatures •. • • 6-8

Dust And Dirt • • • 6-8

High Altitude .., 6-8

Power Rating Factors 6-8

7 ADJUSTMENTS 7-1

Generator Voltage Check and Adjustment 7-1

Governor - • • 7-2

Valve Clearance Adjustments 7-3

Centrifugal Switch 7-4

Charge Rate Adjustment 7-4

8 TROUBLESHOOTING .. . . 8-1

Safety Considerations 8-1

9 MAINTENANCE 9-1

General 9-

1

Generator Set Inspection 9-3

Lubrication System 9-3

Fuel System

• •

• 9-6
Air Cleaners - • 9-9
Contractor Model Air Cleaner 9-9
Governor Linkage 9-10

Batteries 9-11

Crankcase Breather 9-12

Crankcase Breather Tube 9-12

Torsional Washers 9-13
OuHaf-Service Protection 9-14

Returning a Unit to Service . • • 9-14

10 MAINTENANCE RECORD 10-1
11 WIRING DIAGRAMS 11-1

General 11-1

Safety Precautions

Before operating the generator set, read the
erator's Manual and become familiar with
equipment. Safe
achieved only
ated

and

maintained. Many accidents are caused
by failure
tions.

The following symbols, found throughout this man­ual,
the operator, seivice personnel,

rUJMtHil This symbol warns
hazards which will result

jury

IAWARNINGI This symbol refers

safe practice which
sonal Injury

to

alert you

or

death.

and

efficient operation

If

the equipment

follow fundamental rules

to

potentially dangerous conditions

In

can

or

death.

is

properly oper-

and

or

the equipment.

of

immediate

severe personal

to

a hazard or un-

result

in

severe per-

Op-

it

and

can be

precau-

in-

the

to

•

Be

sure all fuel supplies have a positive shutoff

valve.

•

Be

sure battery area

prior

to

servicing near
emit a highly explosive hydrogen
be ignited

EXHAUST

• Provide
erly expel discharged gases away from
closed
dividuals are likely to congregate. Visually
audibly inspect
the maintenance schedule. Ensure that

haust manifolds
Do

not use

ment.

•

Be

sure

by

arcing, sparking, smoking,

GASES

an

adequate exhaust system

or

sheltered areas

exhaust gases

the

unit

has

been well-ventilated

it.

Lead-acid batteries

ARE

DEADLY

and

the

exhaust daily

are

secured

is

well ventilated.

areas where

and not

to

heat a compart-

gas

for

that

can

etc..

to

prop-

en­ and

leaks

per

ex-

warped.

in-

IACAUTIONI This symbol refers

safe practice which can result In personal injury
or product or property damage.

FUEL

AND

Fire,

explosion, and personal injury or

sult from improper practices.

•

DO NOT

unless tanks

ment. Fuel contact with

is a potential fire hazard.

• DO NOT permit any
spark, arcing equipment,
source near the generator

• Fuel lines must

free

should
Do

copper will become brittle

brated

FUMES

fill fuel tanks while engine

of

leaks. Fuel connection
be

made with

not use

or

repeatedly bent.

ARE

are

outside

flame,

be

adequately secured

an

copper piping

to

a hazard or un-

FLAMMABLE

death

the

engine compart-

hot

engine

cigarette, pilot light,

or

other ignition

set or

at the

approved flexible line.

on

flexible lines

if

continuously

can

is

running,

or

exhaust

fuel tank.

and

engine

re-

as

vi-

MOVING
PERSONAL

• Keep your hands, clothing,

• Before starting work on

• Make sure that fasteners

•

Do

•

If

PARTS

from moving parts.

connect battery charger from
then disconnect starting batteries, negative
cable first. This

are secure. Tighten supports
keep guards
etc.

not wear loose clothing

cinity

of

moving
trical equipment. Loose clothing
can become caught
can short

shock

or

adjustment must

running,

folds,

moving parts,

CAN

INJURY

in

out

electrical contacts

buming.

use extreme caution around hot mani-

CAUSE

OR

DEATH

the

will

prevent accidental starting.

position over fans, drive belts,

parts,

or while working on elec-

in

moving parts. Jewelry

be

made while

etc.

SEVERE

and

jewelry away

generator set, dis-

its AC

on the

or

generator

and

jewelry

source,

clamps,

in the

and

and

the

(-)

set

vi-

jewelry

cause

unit

is

in

LS-10

ELECTRICAL
SEVERE

• 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. High voltages can cause in­jury or

• 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.

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 SAFETY

• 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.

SHOCK

PERSONAL

death.

DO NOT tamper with interlocks.

Hazardous voltages can flow from

CAN

INJURY

PRECAUTIONS

CAUSE

OR

DEATH

Benzene and

have been identified by some state and federal
agencies as causing cancer or reproductive
toxicity. When checking, draining or adding
gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.

Used engine oils have been identified by some
state or federal agencies as causing cancer or
reproductive toxicity. When checking or
changing engine oil, take care not to ingest,
breathe the fumes, or contact used oil.

Provide appropriate fire extinguishers and in­stall them in convenient locations. Consult the
local fire department for the correct type of ex-

tinguisher to
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
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.

Substances in exhaust gases have been iden-

tified by some state or federal agencies as
causing cancer or reproductive toxicity. Take
care not to breath or ingest or come into contact
with exhaust gases.

lead,

found in some gasoline,

use.

Do not use foam on electrical

and

keep the floor

KEEP

THIS MANUAL

NEAR

THE

GENSET

iv

FOR

EASY REFERENCE

1.

Introduction

ABOUT

This manual provides installation instructions, and
information on
the Onan® RDJC generator set
manual carefully and comply with each of its warn­ings and
and performing regular maintenance can result in
longer unit life, better performance, and safer op­eration.

The generator set has been carefully designed to
provide safe and efficient service when properly in­stalled and operated. However, the overall safety
and reliability of the complete system is dependent
on many factors outside the control ofthe generator
set manufacturer. To avoid possible safety haz­ards,

make all mechanical and electrical connec-

tions to the generator set exactly as specified in this

manual.
exhaust, electrical, etc.) must comply with all appli­cable codes. Make 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.

operating,

cautions.

SAFETY

All systems external to the generator (fuel,

THIS

Using the generator set properly

CONSIDERATIONS

MANUAL

maintaining and adjusting

(genset).

Study this

HOW TO OBTAIN

When the generator set requires
your nearestl Cummins®/Onan® dealer or distribu­tor. Factory-trained Parts and Service representa­tives are ready to handle all your seivice needs.

If you are unable to locate a dealer or distributor,
consultthe Yellow Pages. Typically, our distributors
are listed under:

GENERATORS-ELECTRIC or

ELECTRICAL PRODUCTS

Forthe name of your local Cummins/Onan or Onan­only distributor in the United States or Canada, call

1-800-888-ONAN
touch-tone phones only). By entering your area
code and the first three digits ofyour local telephone

number, you will receive the name and telephone

number of the distributor nearest you.

For outside North America, call Onan Corporation,

1-612-574-5000, 7:30 AM to 4:00 PM, Central

Standard Time, Monday through Friday. Or, send a

fax to Onan using the fax number 1 -612-574-8087.

When contacting your distributor, always supply the

complete Model Number and Serial Number as

shown on the generator set nameplate.

(this automated service utilizes

SERVICE

servicing,

contact

IAWARNING

INCORRECT SERVICE OR PARTS REPLACEMENT CAN RESULT IN SEVERE PERSONAL IN­JURY, DEATH, AND/OR EQUIPMENTDAMAGE. SERVICE PERSONNEL MUST BE QUALIFIED

TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

Onan is a registered trademark of Onan Corporation.
Cummins is a registered trademark of Cummins Engine

Company,

Inc.

1-1

2.

Specifications

DIMENSIONS

Height 40.12 inches (1019 mm)
Width 27.00 inches (686 mm)
Length 56.62 inches (1438 mm)
Weight 940 lbs (426 kg)

ENGINE

Number of Cylinders 4
Engine Speed (50/60 Hz) 1500/1800 rpm
Recommended Fuel #1 or #2 diesel
Exhaust Connection (pipe tapped) 1.5 in. (38.1 mm)

Fuel Pump Maximum Lift 6 feet (1.8 mm)
Oil Filter Full flow type
Fuel Consumption (full load) 1.6 gallons/h (6 liters/h) (60 Hz)

1.4 gallons/h (5 liters/h) (50 Hz)

ELECTRICAL

Starting Voltage 12 Volts DC
Cranking Current 225 amps at ambient temp, of 32° F (0° C)
Battery 12 Volt, negative ground
Battery Size 560 amps (cold cranking) at 32° F (0° C)

Battery Charge Rate 2 to 5 amps (adjustable)

GENERATOR

Power

15.0 RDJC 15kW(60Hz)

12.5 RDJC 12.5 kW (50 Hz)

Output Rating 1.0 power factor (single-phase)

CAPACITIES

Coolant System (Includes Radiator) 13 U.S. quarts (121)
Oil Capacity 6.5 U.S. quarts (6.0 I)

TUNE-UP

Start-Disconnect Centrifugal Switch Point Gap
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 0.011 in. (0.28 mm)
Exhaust 0.016 in. (0.41 mm)

Injector Firing Order 1, 2, 4, 3

SYSTEM

SPECIFICATIONS

800 amps (cold cranking) at 0° F (-18° C)

0.8 power factor (three-phase)

0.020

in. (0.51 mm)

2-1

3. Installation

GENERAL

Most generator set installations must be designed

so that the generator set will function property under

all anticipated operating conditions. Use these

instructions as a general guide only. Follow the

instmctions of the consulting engineer when locat-

ing or installing any components.

Generator set installations must conform to local

building codes, fire ordinances, and other local,

state and federal regulation. For more detailed

installation instructions, consult Onan Application

Manual T-030, or contact an authorized Onan ser-

vice representative.

Requirements to be considered priorto installation:

• 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

• Noise levels

• Vibration isolation

• Electrical connections

LOCATION

Provide a location for the genset that is dry, clean,
dust-free, well-ventilated, and protected from the
weather (see Figure 3-1). Generator set location is
decided mainly by related systems such as ventila­tion,

wiring,

fuel,

and exhaust. The set should be lo-

cated 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.

COOL AIR IN

GENERATOR SET

NOT LOCATE CLOSER

THAN 24"

[61

OMM] TO

ANY WALL)

AUTOMATIC LOAD

TRANSFER SWITCH

METER

CANVAS

SECTION

HEATED

AIR OUT

RETURN

LINE

TO FUEL TANK

G1079-1

FIGURE

3-1.

TYPICAL

3-1

INSTALLATION

MOUNTING

Generator sets are mounted on a steel skid that pro­vides proper support. The engine-generator as­sembly is isolated from the skid frame by mbber
mounts that provide adequate vibration isolation for
normal installations. For critical installations, install
vibration isolators between the skid base and
foundation.

Mount the genset on a substantial and level base
such as a concrete pad.

Use

3/4-inch

diameter, anchored mounting bolts to
secure the generator set skid to the floor to prevent
movement. Secure the skid using a flat washer and
hex nut for each bolt (Figure 3-2).

FLATWASHER

HEX NUT

SKID

12 INCH

(305 mm)

MOUNTING BOLT

FIGURE

3-2.

BOLT

in 627

DIAGRAM

3-2

VENTILATION

Generator sets create a large amount of

heat,

which
must be removed by ventilation. An outdoor instal­lation can rely on natural air circulation, but indoor

installations need enough properly sized vents in
the correct positions to maintain the necessary air
flow.

The presence or absence of a fan and radiator de­termines ventilation system design. With a radiator,
engine-pusher fan size is large enough to remove

heat from the engine, generator, and a few feet
(roughly a metre) of uninsulated exhaust pipe. Re-

strictive ducting or heat sources otherthan the

gen-

erator set require extra fans to increase airflow.

With other cooling options, ventilation fans are

needed.

Fan size must be large enough to remove
the heat in the room given off by the generator set,
uninsulated exhaust pipes and any other heat-pro­ducing equipment. A temperature differential of 20°
to 30° F

(110 to 17° C) is usually satisfactory.

IACAUTIONI Operating the generator set with

any of the cooling system components re­moved can cause equipment damage. Do not

operate the generator set with any of the cool­ing system components removed.

RADIATOR

COOLING

Cooling air travels from the rear to the front of the
set. Locate the room/compartment air inlet where it
is most convenient, preferably to the rear of the set.
The minimum inlet opening should be at least 1 -1/2
times the size ofthe radiator

area.

Increase the size
of the opening if it will be restricted with louvers or
filters (see Figure 3-1).

Engine heat is removed by a pusher fan which
blows cooling air through the front of the radiator.
The cooling air outlet should be directly in front of
the radiator, and as close to it as is

practical.

The un-

restricted outlet opening must be at least as large as
the radiator opening. A flexible section must

con-

nect the radiator and the air outlet opening, to pre­vent recirculation of heated air.

Generator cooling air is discharged through the en­gine-to-generator adapter on the left side of the en­gine.

3-3

EXHAUST

Pipe exhaust gases outside the enclosure. The ex­haust outlet is 1 -1/2-inch pipe size. Locate the ex-

haust outlet far from the air inlet to avoid gases re­entering the enclosure. Use flexible seamless tub­ing to connect between the engine exhaust and any
rigid pipe extension to prevent transmission of vi­bration.

IAWARNINGI Exhaust gas Is poisonous. Inhala-

tion .can result In severe personal Injury or
death. Modifying the exhaust system can allow

poisonous exhaust gases to escape. Use only

original equipment replacement parts when
servicing the exhaust system. Unauthorized
modifications will also void the warranty and
cancel the UL Listing/CSA Certification. Liabil­ity for injury or damages due to unauthorized
modifications becomes the responsibility ofthe

person making the change.

Because an exhaust system is subjected to detri-

mental conditions such as extreme heat, infrequent
operation,

and light operating

load,

inspect the ex-

haust system frequently to be sure that it remains
fume-tight.

I AWARNING] Inhalation of exhaust gases can re-

sult In severe personal Injury or death. Do not
use exhaust heat to warm a room, compartment
or storage area.

An approved thimble must be used (Figure 3-3) to
pass exhaust pipes through walls or partitions.

Build this thimble according to code (see National

Fire Protection Association bulletin, Volume 4, siec­tion 211 on "Standards for Chimneys, Fireplaces,
and Vents").

As the exhaust pipe length and number of bends in­creases, a larger pipe is required to reduce exces­sive exhaust restriction and back pressure. Exces­sive exhaust back pressure will reduce the air-fuel
ratio,

resulting in reduced output, smoke, wasted
power, high exhaust temperatures and reduced en­gine life.

Total back pressure of ail system components must
not exceed maximum back pressure limits. Note
that any exhaust restriction, even if less than maxi­mum,

will affect performance.

AVOID SHARP BENDS

IF EXHAUST LINE MUST BE PITCHED

UPWARD CONSTRUCT A TRAP OF PIPE

FITTINGS AT POINT OF RISE

(228.60

mm)

h-9" —

INNER SLEEVE

9"^

DRAIN CONDENSATION TRAP

SINGLE THIMBLE DIAMETER

12 INCHES (305 MM)

LARGER THAN EXHAUST LINE

HOLES IN END

EXHAUST

THROUGH

PERIODICALLY

LINE

WALL

PASSING

OR PARTITION

EXS1175

FIGURE

3-3.

EXHAUST

PIPING

3-4

FUEL

IAWARNINGI Fuel tanks present the risk of explo-

TANK AND

LINES

sion 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 supply,

to

avoid leaks due to
vibration and/or fuel line fallure. Do not allow
the fuel line to contact rough, sharp or hot sur­faces.

The top of the fuel tank must be lower than the fuel

pump to prevent siphoning if a system leak occurs.
Install a shutoff valve at the
icing.

If the fuel tank is shared, do not connect it to

an existing

line

at a point above the fuel supply level,

fuel

tank,

to enable serv-

to avoid starving either engine.

Use an approved flexible fuel line next to the en-

gine.

Diesel engines require a fuel supply line and a
separate fuel return line. Install the fuel supply line
from

the supply tankto the inverted flare male elbow

mounted in the inlet ofthe fuel pump. The pump is

threaded

7/16-24

NPTF (American Standard Inter-

nal Tapered Pipe Thread).
Install fuel retum line from the

7/16-24

size opening
in the overflow fitting located on injection pump
(where nozzle fuel retum 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.

IAWARNINGI Always use flexible tubing between

engine and fule supply to avoid line failure and
teaks due to vibration.

IACAUTIONI Never use galvanized or copper fuel

lines, fittings or fuel tanks. 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
putting the set into

operation.

Any dirt or contamina-

tion may cause major damage to the fuel injection

system.

IACAUTIONI Dirt In the system can severely dam-

age both the Injection pump and the Injection
nozzles. Dirty fuel Is one of the major causes of
engine fallure. 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.

FUEL RETURN

LINES

NOZZLES

CONNECT FUEL

RETURN LINE

HERE (FLEXIBLE)

INJECTION

PUMP

F8I111

FIGURE 3-4. FUEL LINE CONNECTIONS

3-5

Separate

The fuel tank top must be lower

Fuel

Tanks

than

the fuel pump
level to prevent putting a static head on the fuel
pump

inlet.

Ifthe

fuel

tank

is

shared

gine,

use separate fuel lines for both engines tp

with

another

en-

avoid starving either one.
The following restrictions apply to separate fuel

tank installation:

1.

The bottom of the fuel tank must not be more

than 6 feet (1.8

m)

below

the

fuel

transfer pump
inlet, unless an auxiliary electric fuel pump is
added.
fer pump

The maximum lift capacity of

is

six

feet.

See

the

Wiring Diagram for

the

trans-

the connection.

2.

If the tank is installed above the fuel pump inlet

level without a supply line shutoff

tured pump diaphragm could cause

valve,

oil

dilution,

a rup-

fuel loss, and fuel leakage to the crankcase.

3. If the maximum fuel lift must be exceeded on
any

installation,

ual

T-030

consult

Onan

Application Man-

for information on installing a day

tank and an electric solenoid shutoff valve.

4.

Use an electric or manual shutoff valve if the

minimum

fuel

level in the tank

is

higherthan the

pump inlet, to provide positive fuel shutoff

when the engine is stopped. This valve also
prevents loss of fuel from possible leaks be-

tween the tank and the fuel pump.

IAWARNINGI Fuel

hazards which can

leaks create lire

result

In

severe

and

explosion

personal In-

jury or death. Always use flexible tubing be-

tween engine

ure and

must

Extend
has a

IAWARNINGI Do notposltlon

leaks

meet applicable codes.

the

1/2-inch

drain

and fuel

due

OIL

to suit the

supply to

to vibration. The

DRAIN

installation.

pipe size tapped hole.

the

oil

avoid

fuel

The

drain

line fail-

system

oil

base

so

that

oil might drip onto the muffler, any exhaust
components,
fire

hazard.

personal

IAWARNINGI Fuel and oil must be

disposed of properly to avoid
damage and
state and local
tanks

and secondary containment and disposal

or any other hot parts,

Fire

presents

Injury

or

death.

clean-up liability.

regulations

causing

the hazard of

severe

contained and

environmental

Check all federal,

regarding storage

requirements.

a

3-6

4.

Preparation

GENERAL

The genset electrical system includes connecting
the

load,

installing the control wiring and connecting
the batteries. Connect the batteries last to avoid ac­cidental starting of the unit during installation.

IACAUTIONI Always disconnect a battery

charger from Its AC source before disconnect­ing the battery cables. Otherwise, disconnect­ing the cables can result In voltage spikes high
enough to damage the DC control circuits ofthe
set

IAWARNINGI Accidental starting of the generator

set while working on It can cause severe per­sonal Injury or death. Prevent accidental start­ing by disconnecting the starting battery cables

(negative [-] first).
Arcing can Ignite the explosive hydrogen gas

given off by batteries, causing severe personal

Injury. Arcing can occur If the negative (-) bat-

tery cable Is connected and a tool being used to

connect or disconnect the positive (+) battery
cable accidentally touches the frame or other

grounded metal part of the set To prevent arc-

ing, always remove the negative (-) cable first,

and reconnect It last.

The following paragraphs contain the procedures
that are used to connect the electrical system ofthe
genset.

Connecting the genset electrical system involves:

• Installation of transfer switch (standby service
only)

• Generator voltage connections

• Load connection

• Control wiring

• Battery connection

Local regulations often require that wiring connec-

tions be made by a licensed electrician, and that the

installation be inspected and approved before op­eration.
etc. must conform to the requirements of electrical
codes in effect at the installation site.

IAWARNINGI Improper wiring can cause a fire or

electrocution, resulting In severe personal Inju­ry or death and/or property and equipment dam-

age.

Before starting the genset, verify that all electrical
connections are secure, and that all wiring is com­plete.
have been removed during installation. Check that
the load cables from the genset are properly
nected.

All connections, wire sizes, materials used,

Replace and secure any access panels that

con-

IAWARNINGI Each of the operations described In

this section should be done only by persons
trained and experienced In electrical mainte­nance. Improper procedures may result In prop­erty damage, bodily Injury or death.

IAWARNINGI Backfeed to utility system can

cause electrocution or property damage. Do
not connect to any building electrical system
except through an approved device and after
building main switch Is opened.

4-1

TRANSFER

If the installation is for standby service, a transfer
switch must be used for switching the load from the
normal power source to the genset (see Figure 4-1).
Either a manual or automatic transfer switch may be
used.

Follow the installation instructions provided

with the transfer switch when connecting the load

and control
Delay Module'"\n this section, for generator set re­mote start connections.

wiring.

Referto heading "Preheat/Time-

SWITCH

NORMAL
SOURCE

1

•LOAD

GENSET

. - J

;8C-1101

(FIGURE

4^.1

.^PICAULOAD TRANSFER

^FUNdriON

4-2

GENERATOR

IACAUTIONI Reconnecting factory connected

VOLTAGE

CONNECTIONS

generator sets to lower voltages may reduce set
ratings, and also render line circuit breakers too
small. Consult with your distributor before per-

forming reconnection for different voltage.

The generator output voltages and maximum cur­rent rating are specified on the generator name­plate.

Line-to-neutral voltage is always the lower
voltage shown on the nameplate. Line-to-line volt­age is the higher rating.

The

factory
panels
the customer. Standard
are shipped

separated

ships

especially

with

in the

special-order

wired

forthe

sets

sets

voltage

without
the T1-T4 or T1-T12
output

box.

These

with

control

specified

by
instruments
output

leads

single-phase

and broad-range generators may be connected to

provide any
connection
check
any

necessary

sired

voltage.

ofthe

output

voltages

Diagram. The Installer must

the stator lead

connections

reconnections to obtain the de-

shown

in

the Re-

always

and perfonn

Refer to the Reconnection Diagram when reviewing
the voltage connection information, and use the

electrical schematic supplied with your genset

when actually performing load connections. (A re­connection diagram is located on the inside of the
power output box cover.)

A DANGER

HAZARDOUS VOLTAGE! Touching

uninsulated live parts Inside the control and

power output boxes can result In severe per-

sonal Injury or death. Measurements and ad-

justments must be done with care to avoid

touching uninsulated live parts.
For your protection, stand on a dry wooden plat-

form or rubber insulating mat, make sure your
clothing and shoes are

dry,

remove jewelry from

your hands and use tools with Insulated

handles.

The genset control panel box contains the auto-

matic voltage regulator (AVR) printed circuit board.
The AVR controls the output of the generator so that
a constant voltage is maintained under varying load
conditions. There are two types of AVR's available;
one requiring jumper adjustments when connecting

or changing load connections. If the genset
tains the AVR shown in Figure 4-2, be sure to

con-

con­nect jumper W10 between terminal V4 (common)
and

V1,

V2, or V3 as listed on the reconnection dia-

gram.

AUTOMATIC VOLTAGE REGULATOR

(VR21)

V3 V1 W10 V2

O

V4

(COM)

FIGURE

4-2. AVR

SELECTION

4-3

JUMPERS

(P/N

300-1540)

IAWARNINGI

LOAD

HAZARDOUS VOLTAGE! Touching

CONNECTION

uninsulated live parts Inside the AC power out-

put box can result In severe personal Injury or

death. Shut down the set and disconnect ALL
power sources to the generator set before re­moving the cover of the AC power output box.

See Figure 4-3.

Load wires can be brought into the power output
box through the holes that are shown in Figure 4-3.

Use flexible conduit and stranded load wires near

the set to isolate vibration and permit movement.

Use suitable size insulated wires forthe load rating
applied.

When installing sets with AC meters.'the generator
output leads must be routed through current trans­formers for proper meter operation. The transform­ers are labeled

CT21,

CT22and CT23. Referto

Fig­ure 4-3 and the reconnection diagram to identify the
output leads that must be routed through each cur­rent transformer, and also appropriate transformer
post selection for meter sensing leads.

Without optional main circuit breaker: Connect

each load wire to the proper generator output lead
inside the output box. Insulate bare ends of un-

grounded wires. Use bolt provided on the output

box to connect the generator ground lead or earth

wire.

Install a fused main switch (or circuit breaker)

between the generator and

load.

If a test-run

indi­cates wrong rotation of 3 phase motors in the load
circuit, switch the connections at any two ofthe

gen­erator terminals.

With optional main circuit breaker: To attach the

load wires to the optional circuit breaker, remove

the access plate that is located directly below the
circuit breaker. Attach the load cables to the base of
the circuit breaker and install the access panel. If a
test-run indicates wrong rotation of 3 phase motors

in the load circuit, switch the connections at any two

of the generator terminals.

IAWARNINGI Backfeed to utility system can

cause electrocution or property damage. Do not
connect to any building electrical system ex­cept through an approved device and after
building main switch Is opened.

IACAUTIONI Phase rotation of the genset and

utility must be the same. Equipment damage

can occur. Check and reconnect as necessary.

Check the rotation of 3-phase motors before
loading and reconnect If necessary.

Balancing

Loads

When connecting loads to the genset, balance the

loads so that the currentflowfrom each line terminal
(L1,

L2 and L3) is about the same. This is especially

important if both single phase and three phase

loads are connected. Any combination of single

phase and three phase loading may be used as

long as all line currents are roughly the same (within

10 percent of median value) and no line current ex­ceeds the nameplate rating ofthe generator. Check
the current flow from each load cable after connec­tions are made, by observing the control panel am-

meter.

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 de-

sign and installation 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 of the consulting engineer when

installing the grounding system.

IAWARNINGI Contact with electrical equipment

can result In severe personal Injury or death. It

Is extremely Important that bonding and equip-

ment grounding be properly done. All metallic
parts that could become energized under ab-

normal conditions must be properly grounded.

4-4

LINE CIRCUIT

BREAKERS (WHEN

PROVIDED)

TERMINALS FOR

CONNECTING GENERATOR

LEADS ON OPTIONAL

CIRCUIT BREAKER

CT22-I

PRP/BLK

AC CONTROL

WIRING HARNESS

GENERATOR LEAD

ENTRANCE

LOAD WIRING

ENTRANCE

Frem

Conlrol:

Gi-or/Blk

Loads

And OO

Grar/Blk

Bolo.
Abovo

Aro CT.'

Loodo
300 VAC
300 VAC

To:

Coooon
Connoct

-2 For

-3 For

LOAD TERMINALS ON

OPTIONAL CIRCUIT

BREAKER

FIGURE

4-3.

POWER

CURRENT

TRANSFORMERS CT21,

CT22 AND CT23 (WHEN

PROVIDED) THE POLARITY

DOTS MUST BE DOWN.

OUTPUT BOX

4-5

CONTROL

The generator set control panel box contains

WIRING

con­nection points for remote control and monitor op­tions.

These connection points are located on the
engine control monitor board (ECM), the preheat/
time-delay module and the optional auxiliary relay
board (ARB). (Note that if the optional ARB is
installed,

no remote monitor connections are at-

tached to the ECM. The ARB provides all remote

monitor connection points.)

If the distance between the genset and the remote
station Is less than 1000 feet (305 m), use 18 gauge
stranded copper

wire.

If the distance is 1000 to 2000

feet (305 to 610 m), use 16 gauge stranded copper

wire.

Always run control circuit wiring in a separate
metal conduit from AC power cables to avoid Induc­ing currents that could cause problems within the
control.

IAWARNINGI HAZARDOUS VOLTAGE Touching

uninsulated live parts Inside the control panel
box can result In severe personal Injury or
death. Control wire Installation must be done

with care to avoid touching uninsulated live

parts.

For your protection, stand on a dry wooden plat­form or rubber Insulating mat, make sure your

clothing and shoes are dry, remove jewelry from
your hands and use tools with Insulated han­dles.

ENGINE

MONITOR

BOARD

(ECM-A11)

The heart of the engine control system is the engine

monitor (A11). It is a printed circuit board assembly
mounted on the back wall ofthe control box (Figure

4-4).

It starts and stops the engine in response to

the control panel switches, engine sensors and re-

mote control signals.

Remote Monitor Connections

The optional Detector 12 Control (12 light panel)

provides the capability of attaching a remote moni-

tor panel. Connections are made on the terminal
block (TB2) located on the ECM board. See Page

11-3 for typical connections at TB2 of the ECM

board.

(If the optional ARB is

installed,

remote mon-

itor connections attach to the ARB, not the ECM.)

4-6

TB1

5.

Is

s

o

Ft

o

KE

•

U3

18

A

: V—\

15A TBI-7.B*

Cl

CRI

a

R5

[ZZ

Ri

EZZ

5

ll R in iii

TBI

O

W8

2 LilB

W9

I

8 | 7 | 6 |

Kl

51|

TBS

PI

FLT

4 ||

K4

LJ

g|lN

K3

CR2

5» CONTROL

F4

K7

Wl

CR3 IZI

CRI

a

RA

CRS

CREB

VR3

a

IC10

RB
R7
RG

ui

[ZZl

C3SR9

eg,

n ,

CRS

K12

•

CRB

a "

CRB

C5

C7

KM KIG KIB

CB

Rl

U3

U5

I I

V RH"

WG

W7

Kea

CRM

F5I

W5

s

B

CRIB 7 P3

V2

K5

CRIP

CRIP

1

8 3 4 5 6 7 B 9 IB 11 IE 13 H 15 IB

OUT)

CRI3

K9 Kll

OUT 1 LAMP OC i OS HET LOP PREHET

1

TEST

*

RESET

K13 KIS

CD

cr

LJ

O"'

3 || 2 || 1 |

1

K17

GO

CR17

•I

PRELOP SU OFF LET

PE

Li

cr

LJ

K19

CR7

OUT| SHUT

LOU FUEL

Q

l3

o

i

a

3

5

il

12

9
IB
11

Q

P4

FIGURE

4-4.

ENGINE

TB2

MONITOR

4-7

BOARD

(ECM)

!_•

AUXILIARY

The following describes the design/functional crite­ria forthe auxiliary relay board (ARB) with a Detec-

tor-? or -12 Genset control. When provided, the

board is mounted on the right wall of the control box.
See Figure 4-5. There are two versions of the ARB;

with and without the set of 12 Fault relays. Page

11-4 is a detailed connection diagram for the ARB.

RELAY

BOARD

(OPTIONAL)

• Jumper Position A (Run) - The relay oper­ates as a Run relay, energizing when SW B+ is
applied from the engine monitor.

• Jumper Position B (Common Alarm) - The

relay operates as a Common Alarm relay. The
relay energizes any time there is an engine
shutdown.

gine.

This signal is provided from the en-

Terminal Blocks:

• TB1 - ARB TB1 and engine monitor
identically numbered and provide the same re­mote control connection points. Note that

tional terminals are provided for terminals 5,7,
and 10 of ARB TB1.

• TB2 through TBS - Connection points for re-

• lays Kl through K3. TB2 provides the N/O and
N/C connections (three form 'C contacts for

each relay). TB3 through TB5 provide the com-

mon connection points (TB3 for

and TB5 for K3).

• TB6 and TB7 - Connection points for fault re­lays K4 through K15. Three terminals are pro­vided for each relay, which are labeled COM,
N/C, N/O.

Plug-In Relays (Kl, K2, K3): The ARB can be

equipped with one to three 3-pole, double-throw re-

lays.

These relays
plug-in relays for easy field addition and replace­ment.

Each relay can be operated as a RUN, COMMON

ALARM,
jumper.

The relay contact ratings are:

• 10 amps at 28 VDC or 120 VAC, 80% PF

• 6 amps at 240 VAC, 80% PF

• 3 amps at 480 VAC, 80% PF

Jumper Positions for Plug-In Relays: Jumpers
W1,

their respective relays,

K2,
of 3 positions (A, B, C) independently of each other.

or ISOLATED COIL with the changing of a

W2 and W3 perform the same functions for

and W3 for relay K3. They can be located in any

(K1,

K2, K3) are field changeable

W1

for relay

K1,

K1,

TB1

are

addi-

TB4 for K2

W2 for relay

• Jumper Position C (Isolated) - The relay op­erates as an Isolated relay. The relay coil is en­ergized by a customer applied 6+ signal
through the terminal block; TB3-1 for relay K1,
TB4-1 for relay K2, and TB5-1 for relay K3.

Jumpers W11, W12, and W13 perform the same
functions for their respective relays; W11 for relay

K1,

Wl 2 for relay K2, and W13 for relay K3. They

can be located in two different positions (A, B) inde-

pendently of one another.

• Jumper Position A - The relay operates iso-

lated from the board. The customer provides
the circuit completion through terminal block;
TB3 for relay
for relay K3. The customer can operate the re-

lay with switched ground logic or use this relay
in the middle of more complex logic circuits if

needed.

• Jumper Position B - The relays operate with
the coils connected to ground through the

board connections. The coil will require a B+
signal to energize with the jumper in this

tion.

Fault Relays (K4 through K15):These optional re­lay modules are used to operate a remote alarm an-

nunciator that has an independent power source.
This allows the use of either AC or DC for alarm
drives. The relays are energized through the latch­ing relays on the engine monitor and provided N/O
and N/C contacts for each extemal alarm connec­tion.

The 12 relays with form 'C contacts are rated:

• 10 Amp, 120 VAC

• 10 Amp. 30 VDC

K1,

TB4-5 for relay

K2,

and TB5-5

posi-

4-8

JUMPERS

RUN RELAY
MODULE(S)

JUMPERS

J1,

J2 WIRE

HARNESS PLUG

CONNECTIONS

FROM A11

Fl

K3

W13

O

K3

TBI

F2

F3

Kl

[KT

O

ua

•

o •—a ,

•

o-a • •

B

ca B

[_SW B+

o

l_B+

REMOTE
START

TB2

LGND

comDN
ALARM
RUN

Kl

N/C N/O

B

cm am

N/C

N/O N/C N/O

cdn

A

WC

B cAn

K2

N/O N/C N/O N/C N/O

cin

cAn

A

N/C N/O N/C N/O N/C N/O

TBT

con

N/C N/O

con

N/C N/O

con

N/C N/Q

con

N/C N/O

con

N/C N/Q

con

I

RUN | I PRELOP | I PREHET | I LOP | I «1 | I OS | I OC I

con

N/C N/O

con

N/C N/O

con

N/C N/O

con

TB7

I FLTl

| |

FLTC

| I LET I I

LO FUEI

K3

-

B con

cm

N/C N/O

N/C N/O cm N/C N/O

I I

con

con

SM OFF

F5

A

O

N/C N/O

|

TBS,

TB7 AND

RELAYS K4

THROUGH K15

ARE OPTIONAL

M

ICS KS t7

FIGURE

4-5.

AUXILIARY

RELAY

4-9

JCIB.

BOARD

O

J(I3_

(ARB)

ICK

PREHEAT/TIME-DELAY

MODULE (A15)

Remote Control

Connections

The start delay/preheat is adjustable from 1/2 to 15
seconds and the stop delay from 1 to 30 minutes.
Turn the delay adjusting potentiometers clockwise

to increase delay and counterclockwise to de-

crease delay. Pre-heat occurs during the delayed
start period and continues through cranking.

START DELAY

POTENTIOMETER

o

Remote control connections are made at

the

termi­nal block (TB1) that is located on the preheat/time­delay module (Figure

4-6).

Connect

one

or more re­mote switches across the remote terminal (TBI-5).
ofthe preheat/time-delay module and the

B+

termi-

nal of the ECM (A11).

iSTOP DELAY

POTENTIOMETER

O-

•

IZZ]

O

A11-TB1-2

(DC DISCONNECT)

A11-TB1-3

A11-TB1-5

A11-TB1-7

(B+ OUT)

(RUN)

(GND)

I—I ,-, ,-,

r—i

TBI

4 5

i 1|

REMOTE

CONTROL RUN

SIGNAL

O

TB1-3
(SWITCHED B+)

K13-85
(PREHEAT)

A11-TB1-6
(RMT START)

A11-TB1-7
(B+ OUT)

HGURE

4-6.

PREHEAT/TIME-DELAY

4-10

MODULE

BATTERY

CONNECTIONS

Starting the unit requires a 12 volt battery current.

Use one 12 volt battery for a nonnal installation

(Figure

4-7).

(Referto Section 2, Specifications tor

battery type.)
Necessary batteiy cables and rack are on the unit.

Service battery as necessary. Infrequent use (as in
emergency standby service), may allow battery to
self-discharge to the point where it cannot start the
unit. If installing an automatic transfer switch that

has no built-in charge circuit, connect a separate
trickle charger. Onan automatic transfer switches
can include an optional battery charging circuit.

IAWARNINGI Ignition of

can

cause severe personal Injury. Always

nect battery negative

IAWARNINGI Do not smoke while

batteries.

teries
cause

Explosive gases are emitted

In

operation. Ignition

severe

personal injury.

explosive battery gases

con-

(-) last

to

prevent arcing.

servicing

the

from bat-

of

these gases

can

STARTER SOLENOID

CONNECT NEGATIVE
CABLE TO CONVENIENT'
BOLT ON ENGINE

CONNECTION MUST
BE CLEAN AND
PAINT-FREE

RGURE

4-7.

BATTERY

POSITIVE (+)

CONNECTION

STARTER

MOTOR

TWO,

6 VOLT

BATTERIES

CONNECTIONS

ESI 693

4-11

5. Control Description

GENERAL

The following describes the function and operation
ofthe standard Detector 7 and optional Detector 12
generator set control. All instruments and control

EMERGENCY STOP

PUSHBUTTON

PANEL LAMP

switches are located on the face of the control panel
as illustrated in Figures

5-1

through 5-3. The control

panel description is separated into a DC portion for

monitoring the engine and an AC portion for moni-

toring the generator.

PREHEAT

RUN/STOP/REMOTE

SWITCH

RESET/LAMP

TEST/ PANEL

LAMP SWITCH

COOLANT

TEMPERATURE

GAUGE

FIGURE

5-1.

OIL PRESSURE

GAUGE

RUNNING

TIME METER

DC CONTROLS (DETECTOR 12 SHOWN)

5-1

DC INDICATOR

VOLTMETER LAMPS

DC CONTROLS

Preheat/Reset/Lamp Test/Panel Lamp Switch:

Panel Lamp: Illuminates control panel.

Oil Pressure Gauge: Indicates pressure of
cating oil in engine (wired to a sensor located on the
engine).

Coolant Temperature Gauge: Indicates tempera­ture of circulating coolant in engine (wired to a
sor located on engine).

DC Voltmeter: Indicates the battery charging sys-

tem voltage.

Run/Stop/Remote Switch:

• Push the switch to the Run position to start and
run the generator set.

' • Push the switch to the Stop position to stop the

' set ( The switch must be in the Stop position

when the reset switch is used to restore gener­ator set operation following a fault shutdown,)*

; • Push the switch to the Remote position to allow

a remote eontrollerto automatically run the set.

Running Time Meter: Registers the total number
of hours the unit has run. Use it to keep a record of
periodic servicing. Time is cumulative; meter
not be reset.

lubri-

sen-

can-

• Push the switch to the Preheat position (mo­mentary contact) to manually preheat the en-

gine combustion chambers before starting.

(This is normally accomplished automatically

by the preheat module inside the control box.)

• Push the switch to the Reset, Lamp Test

tion (momentary contact) to reset the engine
control to restore operation following a fault

shutdown (the Run - Stop - Remote switch
must be in the Stop position for reset to occur)

and to test the indicator

has a light which lights following a fault or emer-

gency shutdown. The light remains lit until the
engine control has been reset.

' • Push the switch to the Panel Lamp position to

light the panel illumination lamp.

Emergency Stop Button (Optional): Push-in
switch for emergency shutdown of the engine. The
button lights up when it is pushed in. To reset, pull
switch out and move Run/Stop/Remote switch to
Stop position. Then push Preheat/Reset/Lamp
Test/ Panel Lamp switch to Reset/Lamp Test

tion.

lamps.

Also,

posi-

this switch

posi-

5-2

Detector7 Indicator Lamps ;The standard control
panel has seven Indicator lamps which are de­scribed as follows:

• RUN (green) lamp comes on when starter cir­cuit opens after set starting.

• PRE LO OIL PRES (yellow) indicates engine
oil pressure is marginally low.

• PRE HI ENG TEMP (yellow) indicates engine
temperature is marginally high (or coolant level
is low on optionally wired sets).

o

iemp

Tea*

• LO OIL PRES (red) indicates engine has shut
down because of critically low oil pressure.

• HI ENG TEMP (red) indicates engine has shut
down because of critically high engine

tem-

perature or low coolant level.

• OVERSPEED (red) indicates engine has shut
down because of excessive speed.

• OVERCRANK (red) indicates engine has failed
to start during the cranking period.

Detector 12 Indicator Lamps: Jhe optional twelve
lamp control includes all the features of the seven
lamp control plus the following:

• FAULT 1 (red) lamp indicates an undedicated
fault. May be field programmed as a shutdown
or non-shutdown, and as a timed or non-timed
fault. (Normally set fbr timed shutdown).

• FAULT 2 (red) lamp indicates same features as
Fault 1 (normally set for timed shutdown).

RUN
IfflEtOOLPflBl
jPBEHBMTBKj

OVBSIfED

MULTI
BMJLT2

UWBIQTHi'l

10

WB.

2>

• LOW ENG TEMP (yellow) lamp lights if engine
temperature is marginally low for starting. It
may indicate an inoperative coolant heater.

• LO FUEL (yellow) indicates fuel supply is mar­ginally low.

. • SWITCH OFF (flashing red) indicates genera-

tor set is not in automatic start mode.

5-3

RGURE

5-2. INDICATOR

LAMPS

EXCITATION-

FIELD BREAKER;

AC VOLTMETER AC AMMETER' FREQUENCY

METER

PHASE

SELECTOR

SWITCH

AC

CONTROLS

UPPER AND LOWER

SCALE INDICATOR

FIGURE

5-3.

AC Voltmeter (Optional): Dual range instrument
indicating AC voltage. Measurement range in use
shown on indicator lamp.

AC Ammeter (Optional): Dual range instrument
indicates AC generator line current.

Frequency Meter

(Optional):

Indicates generator

output frequency in hertz.

Voltage Adjusting Rheostat: Provides approxi­mately plus or minus five percent adjustment of the
rated output.voltage.

VOLTAGE

ADJUST

AC

CONTROLS

Upper and Lower Scale Indicator Lamps (Op­tional):

Indicates

which

scale

to

use

on

meter and ammeter.

Phase Selector Switch: Selects phases of
erator output to be measured by AC voltmeter and
ammeter.

Excitation Field Breaker: Provides generator ex-

citer and regulator protection from overheating in
the event of certain failure modes of generator, ex-

citer and voltage regulator.

the

AC

gen-

volt-

5-4

6.

Operation

Exhaust gases contain carbon monoxide, an odorless and colorless gas.
Carbon monoxide Is poisonous and can cause unconsciousness and
death. Symptoms of carbon monoxide poisoning can Include:

IAWARNINGI

EXHAUST GAS IS DEADLY!

• Dizziness

• Nausea

• Headache

•

Weakness

IF

YOU

GET OUT
medical attention. Shut down the unit and do not operate until It has been
Inspected and repaired.

Protection against carbon monoxide inhalation also Includes proper
stallation and regular, frequent visual and audible Inspections of the
complete exhaust sysfem.

This section describes generator set
cluding pre-start checks, starting, running, and
stopping the
before starting the set. Be completely familiar with
the set for safe operation.

IACAUTIONI Always disconnect a battery

charger from Its AC source before disconnect-

ing the battery cables. Otherwise, disconnect­ing the cables can result In voltage spikes high
enough to damage the DC control circuits ofthe
set

set.

Study this entire section carefully

OR ANYONE ELSE

INTO

GENERAL

and Sleepiness

EXPERIENCE

THE FRESH AIR

operation,

in-

IMMEDIATELY.

• Throbbing In Temples

• Muscular Twitching

• Vomiting

• Inability to Think Coherently
ANY OF THESE

If symptoms persist, seek

IAWARNINGI Accidental starting of the generator

set while working on It can cause severe per-

sonal Injury or death. Prevent accidental start­ing by disconnecting the starting battery cables
(negative [-] first).

Arcing can Ignite the explosive hydrogen gas
given off by batteries, causing severe personal
Injury. Arcing can occur If the negative (-) bat-

tery cable Is connected and a tool being used to

connect or disconnect the positive (+) battery

cable accidentally touches the frame or other
grounded metal part of the set
ing, always remove the negative (-) cable first,
and reconnect It last

SYMPTOMS,

In-

To

prevent arc-

6-1

PRESTART

CHECKS

Lubrication

Before starting, be sure the following chiecks have
been made
to the Maintenance section for the recommended
procedures.

Ventilation

Verify all dir vents and ducts are open and free from
any obstructions. Verify dampers, if used, operate
properly.

Mechanical

Check for loose belts and fittings, leaking gaskets

and hoses, or any signs of mechanical damage. If
any problems are found, have them corrected im-

mediately. „ •

Coolant

Check

fhe recommended coolant if low.

the

and

the

Checks

coolant

unit is ready for

level.

Fill

the cooling system with

operation.

Refer

Checkthe engine

possible to

Fuel

Make sure the fuel tank has sufficient fuel and that

the fuel system is primed.

DC

Electrical

Check the terminals on the batteries for clean and

tight connections. Loose or corroded connections

create resistance which can hinder
and reconnect the battery cables if loose. Always
disconnect both ends ofthe negative battery cable.

Reconnect
tery terminal and the other

make

sure
teiy ahd least likely to ignite explosive battery
gases.

Fault Lamps: Push the Reset/Lamp switch on the
control
that

all

Replace any bulbs that are burned out.

the

one

that any

panel.

the

bulbs

oil

level.

Keep

dipstick

high

mark without Overfilling.

System

end

of the

arcing

All indicator lamps

are

on

cable
will

and

end

be

then

the

oil

level

near as

starting.

to

the

negative bat-

to

ground.

away

should

release the switch.

This will

from

light.

Clean

the

bat-

Verify

6-2

STARTING

The following sections cover the three methods
used to start the generator set

IACAUTIONI Phase rotation of the genset and

utility must be the same. Equipment damage
can occur. Check and reconnect as necessary.

Check the rotation of 3-phase motors before
loading and reconnect If necessary.

IACAUTIONI Preheating the engine longer than

one minute before cranking the engine can de-

stroy the manifold heater and glow plugs, be-

cause there

is

no incoming airflow

to

cool them.

For this reason, do not exceed the one minute

preheat periods, to prevent heater burnout and

conserve the battery.

Preheat

The preheat circuit provides a signal during time

delayed start and during cranking to activate the

en-

gine glow plugs and the manifold heater.

Delayed Starting

The time delay start function precludes automatic
start-up of the genset for a determined amount of
time (1/2 to 15 seconds). It is used for installations
that might experience power interuptions of short
duration,

and not want the genset to start and also

for the preheat function noted above.

Starting at Control Panel

1.

Press the Preheat switch (Figure 6-1) to pre-

heat and hold it there for:

• One minute if the outdoor temperature is
belowSSoF^C)

• Thirty seconds if the outdoor temperature
is above 55° F (13° C)

In extreme cold (below 32° F [0° C]) it may be
necessary to maintain preheating for two

min­utes after the engine starts, to obtain firing or
smooth out cylinders, especially at no load or
light loads.

2.

Release the Preheat switch and move the Run/

Stop/Remote switch to the RUN position. This
activates the engine control system and the
starting system. The starter will begin crank­ing,

and after a few

seconds,

the engine should

start. The starter will disconnect when the en-

gine speed reaches 450 to 570 r/min.

Ifthe engine does not start, the starter will dis­engage after a specified period of time and the
control will indicate an overcrank

fault.

Genera-

tor sets with the standard overcrank control will

crank continuously for up to 75 seconds before
disengaging the starter. Generator sets with
the cycle cranking option will crank for 15 se­conds in each cycle until 3 cycles have been
completed.

To clear an overcrank fault, place the Run/

Stop/Remote switch in the STOP position and
momentarily depress the Reset switch. Wait

two minutes for the starter motor to

cool,

then
repeat the starting procedure. If the engine
does not run after a second attempt at start­ing,

refer to the Troubleshooting section.

IACAUTIONI 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 ad-

ditional 12 volt battery In parallel to the starting
battery. Do not apply overvoltage to the starting
circuit at any time.

Starting From Remote Location

Move the Run/Stop/Remote switch on the genset
control panel to the REMOTE position. This allows
the generator set to be started from a remote

switch.

Closing the remote switch initiates the start-

ing sequence described.in the previous section.

Automatic Starting and Stopping

Place the Run/Stop/Remote switch on the genera-

tor set DC panel in the REMOTE position if an auto-

matic transfer switch is

used.

This allows the trans­fer switch to start the generator set if a power outage
occurs and stop it when the power returns.

6-3

Cold

Starting

With

Loads

In addition to the following recommendations, the

RDJC generator set will require the installation of the
constant glow plug kit. This will enable the set to
start and accept a load within 10 seconds when am-

bient temperatures are above 40oF (40C).

In accordance with NFPA 110, Onan recommends
installing diesel standby generator sets (life safety
systems) equipped with coolant heaters in locations
where the minimum ambient temperature is above
40oF (40C). NFPA also requires that the engine
coolant be maintained at a minimum of 90oF (320C)
and for most applications, accept the emergency

load in 10 seconds or less. Although most Onan
generator sets will start in temperatures down to

-250F

(-320C)

when equipped with coolant heaters,

it might take some running time to warm the engine

up before a load can be applied when ambient

tem-

peratures are below 40oF (40C).
The Low Engine Temperature (LET) lamp on the

Onan Detector 12 control is provided to meet the re­quirements of NFPA 110. The LET sensor alarms
when the engine coolant temperature falls below
70oF (210C). In applications where the ambient
temperature falls below 40oF (40C), the LET may
be lit even though the coolant heaters are

nected.

Under these conditions, although the

con-

gen-

erator set may start, it may not be able to accept

load within 10 seconds. When this condition occurs,
check the coolant heaters for proper operation. If
the coolant heaters are operating properly, other

precautions might be necessary to warm the engine

before applying a

load.

AC VOLTMETER AC AMMETER

UPPER AND LOWER

SCALE INDICATOR

EXCITATION

RELD BREAKER

PHASE

SELECTOR

SWITCH

VOLTAGE

ADJUST

EMERGENCY STOP RUN/STOP/REMOTE PREHEAT

PUSH-BUTTON SWITCH RESET/LAMP

FREQUENCY V / TEST/PANEL

METER 1 PANEL LAMP / LAMP SWITCH

INDICATOR

LAMPS

RUNNING

TIME METER

COOLANT OILPRESSURE DC VOLTMETER

TEMPERATURE GAUGE

GAUGE

FIGURE

6-1.

CONTROL PANEL (DETECTOR 12 SHOWN)

6-4

RUNNING

With the genset mnning, listen for any unusual

noises that may indicate mechanical problems and
check the oil pressure frequently. Investigate any­thing that indicates possible mechanical problems.

Oil Pressure
to 55 psi

Gauge:

(241

to 379 kPa) when the engine is at op-

The oil pressure should be 35

erating temperature.
Coolant Temperature Gauge: The coolant

tem­perature should be 170° to 216° F (77° to 102° C)
depending on the load and ambient temperature.

Before operating the genset under

load,

make cer­tain the genset will perform correctly by checking
the following areas.

Exhaust

System

With the generator set operating, inspect the entire
exhaust system visually and audibly including the
exhaust

manifold,

mufflerand exhaust pipe and rain
cap (if equipped). Check for leaks at all connec­tions,

welds, gaskets and joints and also make sure

that exhaust pipes are not heating surrounding ar-

eas excessively. If any leaks are detected, shut
down the genset and have leaks corrected immedi­ately.

I AWARNING I Inhalation of exhaust gases can re-

sult In severe personal Injury or death. Be sure
deadly exhaust gas Is piped outside and away

from any windows, doors or other Inlets to

building.

Fuel

System

With the generator set operating, inspect the fuel
supply lines, return lines, filters and fittings for
cracks and abrasions and make sure they are not
rubbing against anything that could cause break­age.

If any leaks are

detected,

have them corrected

immediately.

IAWARNINGI Ignition of fuel can cause severe

personal Injury or death by fire or explosion. Do

not permit any flame, cigarette, spark, pilot

light, arcing equipment, switch or other Igniter
near the fuel system.

Engine

Gauges

Check the following while the genset is operating.

Refer to Figure 6-1 for location of engine gauges.

DC Voltmeter: This is a voltage reference gauge,
indicating condition of the batteries and also of bat­tery charging circuit. Gauge should read approxi-

mately 12 to 14 volts while genset is running. If
reading is high or low, check batteries and the bat-

tery charging circuit.

Generator AC

Meters

(Optional)

Check the following meters while the genset is op­erating.

Refer to Figure 6-1 for location of the

gen-

erator AC meters.

Frequency Meter: The generator frequency
should be stable and the reading should be the
same as the nameplate rating (50 or 60 hz).

The generator frequency is a result of engine
speed,

which is automatically controlled. Ifthe

gen­erator frequency is below specification, contact an
authorized service center.

AC Voltmeter: Tum the phase selector switch to
each line-to-line phase selection shown on the volts
scale (L1-L2 on single phase gensets: L1-L2,

L2-L3,

and L3-L1 on three phase gensets). Read

the AC voltmeter using the upper or lower scale as

indicated by the scale indicator
line-to-line voltage should be the same as the

light.

At no

load,

gen-

the

set nameplate rating. Ifthe reading is incorrect, re­fer to the Generator Voltage Adjustment procedure
at the end of this section.

AC Ammeter: Tum the phase selector switch to

each phase selection shown on the amperes scale
(L1 and L2 on single phase gensets;

L1,

L2 and L3
on three phase gensets). Read the ammeter using
the upper or lower scale as indicated by the scale
indicator light. At no

load,

the current readings

should be zero. With a load applied, each line cur-

rent should be approximately the same, and no line

current should exceed the genset nameplate rating.

6-5

STOPPING

Emergency

Stop

(Optional)

Before Stopping

Run the genset at no load for three to five minutes

before stopping. This allows the lubricating oil and
engine coolant to carry heat away from the combus­tion chamber and bearings.

Normal

Ifthe genset was started atthe genset control panel
or at a remote control panel, move the Run/Stop/

Remote switch or remote starting switch to the
STOP position. If the stop circuit
ernor arm down to shut off fuel injection pump.

If the set was started by an automatic transfer
switch,
minutes after the normal power source returns. -

Time Delayed Stopping *
The time delay stop function (adjustable from 0.5 to

15 minutes) provides for automatic cool-down mn­ning of the genset for a preset amount of time
(approximately 3 to 5 minutes is recommended).

Stop

fails,

push the gov-

the genset will automatically stop about 15

An optional emergency stop button is located on the
right side of control panel. Push the button in for
emergency stop. Note that no fault indicators will
light when the emergency button is used. To reset

the fault circuitry, pull the emergency stop button

out and move the Run/Stop/Remote switch to the
Stop position. Then move the test switch to Reset/
Lamp Test position.

Engine

With the genset

switch in the Test position (see Figure 6-1). All
cator lamps should light. Verify all of the lamps are
on and then release the switch. Contact an Onan
distributor if any lamps require replacement.

Mechanical

With the genset 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.

Monitor

stopped,

Checks

Indicator

hold the Reset/Lamp Test

Lamps

indi-

6-6

BREAK-IN

Observe the following schedule for genset break-in:

1.

One half hour at 1/2

1.

One half hour at 3/4

3. Full

load.

During the first few hundred hours of

genset load should be at least 1/2 to full

load.
load.

operation,

load.

Con-

the

tinuous operation below this load recommendation,
can result in poor piston ring seating, causing high-

er-than-normal oil consumption and blowby.

• 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 extemal
current leakage

• Breakdown of generator insulation due to
water absorption

Proper exercising does the following:

Drain and replace the crankcase oil afterthe first 50

hours of operation on new generator

sets.

Refer to

the Maintenance section ofthis manual forthe rec-

ommended procedures.

NO-LOAD

OPERATION

Periods of no-load operation should be held to a
minimum.

If it is necessary to keep the engine

run­ning for long periods of time when no electric output
is required, best engine performance will be ob-

tained by connecting a "dummy" electrical

load.

Such a load could consist of a heater element, etc.

EXERCISE

IACAUTIONI Improper exercising of the genera-

PERIOD

tor set 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 temperatuie. Also,

operating the engine at no load or at low tem-

peratures causes carbon buildup and exhaust

system fouling. Continued operation In this
manner may cause starting failure and/or en­gine damage. Exercising a generator set with-

out exercising Its associated controls and

switchgear does not test the operation of the

controls and switchgear. If the control systems

are not fully functional, the system may fall to
provide power when required.

Infrequent use of the generator set can cause it to

deteriorate. The following can occur

• Elevates engine

oil

temperature to at least 180°

F (82.2° C)

• Evaporates water from engine lubrication sys­tem

• Re-establishes a protective oil film on engine
parts

• Recharges battery to full normal potential

• Brings generatorto 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 dur-

ing this exercise.
To exercise the generator set, do the following;

1.

Perform all required maintenance

checks,

start
the unit, and apply a load (50 percent or more)
by creating a simulated power

failure*.

This ex-

ercises the control and switchgear systems.

2.

Afterthe genset has reached its normal operat-

ing temperature, allow the genset to run an
additional 30 minutes.

3. Shut the unit down by simulating the retum of
normal power*. Run the set for approximately

three to five minutes with no load to allow the
engine to cool down.

• This applies to a standby genset only. Other units should
be started and loaded by control and load application sys-

tems normally associated with operation of the unit.

After each exercise period, refill the fuel tank and
checkthe engine for leaks and overall

condition.

Lo-

cate the cause of any leaks and correct.

6-7

HIGH

1.

Make certain that nothing obstmcts air flow to

and from the set.

2.

Be sure that the set location is properly venti-

lated.

3. Check the level of battery electrolyte fre­quently, and add approved water when neces­sary to maintain the proper level.

4.

Keep the cooling system clean and the radiator

filled,

and see that the fan belt tension is prop-

erly adjusted.

LOW

1.

Use the correct viscosity oil for the prevailing

temperature. Change oil only when the engine
is warm. If an unexpected temperature drop
causes an emergency, move the set to a warm
location or apply externally heated air until the

oil flows freely (never use an open flame).

2.

Use fresh

condensation.

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

4.

Use additional preheating for cold starts.

TEMPERATURES

TEMPERATURES

fuel,

and protect against moisture

DUST

1.

Keep the generator set and the codling system

clean.

2.

Service the air cleaner as frequently as neces-

sary

3. Change the crankcase oil every 100 operating
hours.

Maximum power is reduced approximately 4 per-

cent for each 1000 feet (305 m) altitude.

The generator set power rating applies to sets used

in standby applications. The set will operate at the
stated rating forthe duration of normal utility power

interruptions. The rating was established for a stan­dard radiator cooled set mnning on diesel fuel and
operating at an altitude of 300 feet (92 m) with an
ambient temperature of

relative to other applications, altitudes, cooling sys­tems,
ized service center.

Keep the governor linkage clean.

HIGH

POWER

or ambient temperatures, contact an author-

AND DIRT

ALTITUDE

RATING

810 F

FACTORS

(27°^

C).

For a rating-

6-8

7. Adjustments

GENERATOR

If the optional
control panel-mounted potentiometer
for adjusting the AC output (see Figure 7-1). Output
voltage
of nominal voltage
Call your distributor
be obtained

Move
control panel to the Run position. Check the follow­ing conditions while

IAWARNINGI Use extreme caution when working

on electrical components. High voltages

cause Injury

damp clothing (particularly

skln surface

cal equipment

can be

by

the

Run/Stop/Remote switch

to be

VOLTAGE

ADJUSTMENT

AC

meters

adjusted plus

this adjustment.

or

death.

are

by

turning this potentiometer.

if the

the

damp when handling electri-

required voltage cannot

genset

Do not

CHECK AND

installed,

or

minus five percent

is

wet

an

extemal

is

provided

on the

operating.

wear jewelry

shoes) or allow

engine

can

or

1.

Move

2.

Move the Phase Selector

the

Phase Selector switch
erator output current and voltage, and perform
the following steps:

A. Insert a screwdriver into

just potentiometer located
the genset control panel
wrench carefully loosen

B. While observing

the screwdriver clockwise to increase volt-

age

or

counterclockwise

age,

and

adjust

voltage.

If correct voltage cannot

this adjustment, contact

center

tion.

for

assistance.

C. After setting

the locking
change

the

the

voltmeter, slowly turn

to the

be

an

the

correct voltage, tighten

nut,

being careful

adjustment

switch

to

read

the

Voltage

on the

and

the

to

decrease volt-

rated nameplate

attained through

authorized service

to the Off

front

using

locking

not to

nut.

gen-

Ad-

of
a

posi-

Onon

FIGURE

o

2s

VOLTAGE

ADJUST

7-1.

CONTROL

PANEL

o

(DETECTOR

o

12

SHOWN)

7-1

GOVERNOR

The governor controls engine speed. On a 4 pole
generator, 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
tension by turning the governor speed adjusting nut

(Figure 7-2). Turn the nut clockwise (more spring

tension) to increase rpm, or counterclockwise to re­duce govemed speed. Use a stroboscope or a fre­quency meter to make this adjustment.

Sensitivity

If the governor is too sensitive, a rapid Hunting

Adjustment

con­dition occurs (alternate increasing and decreasing
speed).

Adjust the governor for maximum sensitiv-

ity without hunting. After making the sensitivity ad-

justment, readjust the speed.
To adjust governor sensitivity (no-load to full-load

speed droop), tum the sensitivity adjusting ratchet
as follows.

Radiator cooled Sets: Turning the ratchet clock-

wise provides more sensitivity (less speed drop

when full load is applied), and turning it counter-

clockwise provides less sensitivity (more speed
drop).

City Water Cooled Sets: Turning the ratchet coun­terclockwise provides more sensitivity (less speed
drop when full load is applied), and turning it clock­wise provides less sensitivity (more speed drop).

GOVERNOR

SHAFT

DECREASE

SENSITIVITY

SPEED

ADJUSTING

NUT

GOVERNOR

ARM

SENSITIVITY

ADJUSTING

RATCHET ^

GOVERNOR ARM

SPEED ADJUSTING

NUT AND LOCK NUT

RADIATOR COOLED SETS

INCREASE RPM

(Hold spring stud in

GOVERNOR

SPRING STUD

(SENSITIVITY

ADJUSTMENT)

TURN FOR

MINIMUM SPEED

DROP,

THEN

ADJUST SPEED CUT

GOVERNOR

/ SPEED

GOVERNOR

STUD

INCREASE

SENSITIVITY

TURN TO

position)

STUD

DECREASE

7-2

DECREASE

SENSITIVITY

FIGURE

INCREASE

SENSiriVITY SPEED

ADJUSTING NUT

CrTY WATER COOLED SETS

7-2. ADJUSTING

GOVERNOR

INCREASE

SPEED

VALVE

CLEARANCE

ADJUSTMENTS

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

IACAUTIONI incorrect valve clearance adjust-

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

1.

Tum 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
haust valve push rod will be in its lowest
tion,

and the intake valve push rod will be mov-

direction.

The ex-

posi-

ing downward. As the 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.

Tum the flywheel an additional 10 to 45 de-

grees clockwise (estimated). When the piston

is in this position, it is in its power stroke, with
both valves completely closed.

3. Check cylinder head-bolt torque prior to valve
clearance adjustment. Torque values are listed
in the Specifications section. Adjust valve
clearance with the locknut which secures the
rocker arm to the cylinder head (Rgure 7-3).

Loosen this locknut to increase clearance,

tighten it to reduce clearance.

4.

Using a feeler gauge, check the clearance be-

tween the rocker arm and the valve (Figure
7-4). Increase or decrease the clearance until
the proper gap is established. Valve clear­ances are listed in the Specifications section.

VALVE ADJUST VALVE

SPRING CLEARANCE HERE

RETAINER

VALVE

SPRING

RGURE 7-3. VALVE CLEARANCE

ADJUSTMENTS

EXHAUST VALVES

ROCKER

ARM

VALVE

PUSH ROD

VALVE SEAT

VT1044

PCV VALVE

7-3

INTAKE

VALVES

VT1045

RGURE 7-4. CHECK VALVE CLEARANCE

CENTRIFUGAL

SWITCH

The start-disconnect centrifugal switch (Figure 7-5)
is located on the side ofthe

engine,

above the oil

fil-

ter. The switch opens when the engine stops, and

closes when engine speed reaches 900
essary, loosen the stationary contact
point gap to

0.020

inch

(51

mm). Replace burned or

rpm.

and

adjust the

If nec-

faulty points.

IAWARNINGI High

vere

personal Injury or

breaker point

voltage,

gap.

Disconnect the battery cable,

which can cause se-

death,

Is present at the

negative (-) terminal first, before setting the

breaker point

CHARGE RATE

gap.

ADJUSTMENT

The adjustable resistor slide tap (Figure 7-6) in the
charging circuit is set to produce a 2 ampere charg-

ing 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.

FIGURE

COOLING

OUTLET

CHARGING

RESISTOR"

SET GAP AT

7-5.

CENTRIFUGAL

ADJUSTMENT

AIR

CENTRIFUGAL

BREAKER

POINTS

0.020

SWITCH

SWITCH

INCH

(51 mm)'

ESI 808

IAWARNINGI

plosion,

jury. Because

do not

producing devices In

Batteries

which

smoke

present the hazard of

can result In severe personal In-

batteries

or allow any

produce explosive gas,

flame, sparks,

the

battery area.

or arc-

ex-

Avoid overcharging the battery. Make small incre­ments of change until the proper rate has been de-

termined to keep the batteiy charged.

FIGURE

SLIDE

7-6.

CHARGING

TAP

ESI 971C

RESISTOR

8. Troubleshooting

The generator set has sensors that continuously
monitorthe engine for abnormal conditions, such as

low oil pressure or high coolant temperature. If
these conditions occur, the engine monitor
vates a fault lamp, and may also stop the engine

(depending on the

stopped forthis

restart the set after making adjustments or correc-

tions.

This section describes the fault condition sys-

tem,

and suggests troubleshooting procedures.

fhe standard seven light control has a single green

light to indicate

fault lights. The optional twelve-light control has a

single green light to indicate
and seven red fault
terminal connection for a customer supplied
ble alarm, which sounds when a fault occurs.

SAFETY

High voltages are present inside the control box and
generator output box when the set is mnning. Do
not open the control box or generator output box
while the set is mnning.

IAWARNINGI Contacting high voltage components

can cause electrocution, resulting In severe per­sonal Injury or
covers In place during troubleshooting.

Generator set installations are normally designed
for automatic starting or remote starting. When

troubleshooting a set that is shut down, make cer-

condition).

reason,

RUN,

death.

two amber lights and four red

lights.

CONSIDERATIONS

Keep control and output box

Ifthe generator set is

the operator may be able to

RUN,

Both controls also have a

four amber lights

acti-

audi-

tain the generator set cannot be accidentally re­started.
STOP position and remove the negative battery ca­ble from the set starting battery.

IAWARNINGI Accidental starting of the generator set

during troubleshooting can cause severe personal
injury or death. Disable the generator set before

troubleshooting.

When a fault lamp tums on during operation, follow
the procedures listed below to locate and correct
the problem. For any symptom not listed, contact

an authorized service center for assistance.

Resetting the Control

The external alarm and fault lamp may be deacti-

vated by moving the Run/Stop/Remote switch to

the Stop position and pressing the Reset/Lamp

Test/Preheat switch. Locate the problem and cor­rect it before restarting the set. While pressing the

Reset/Lamp Test/Preheat

all lamps light.

Line

The line circuit breaker mounts on the generator
output box. If the load exceeds the circuit breaker
current rating, the line circuit breaker
venting the generator from being overloaded. If the
circuit breaker trips, locate the source of the over­load and correct as necessary. Manually reset the
breaker to reconnect the load to the generator.

Place the Run/Stop/Remote switch in the

Circuit

Breaker

switch,

(Optional)

make certain that

will

open, pre-

8-1

TABLE

^WARNING: Many troubleshooting procedures present hazards which can result In severe personal

8-1.

TROUBLESHOOTING

Injuryordeath. Only qualified service personnel with knowledge of fuels, electricity, and machinery

SYMPTOM

1.

Green RUN lamp lights following engine

startup.

2.

PRE HI ENGINE TEMP lamp lights. En-

gine continues to operate.

3. HI ENG TEMP lamp lights. Engine
shuts down.

CORRECTIVE

1.

Indicates all engine systems are normal. No correc-

tive action required.

2.

Indicates engine is operating near its capacity and

temperature has risen to approximately 220oF (104°

C)

or coolant level is low on optionally wired sets. If
generator is powering non-critical and critical loads
and cannot be shut down, use the following:

a. Reduce load if possible by turning off non-critical

loads.

b. Check air inlets and outlets and remove any ob-

structions to airflow.
If engine can be stopped, follow procedure In

step 3.

3. Indicates engine has overheated (engine tempera­ture has risen above 230oF/110oC) or coolant level is

low. Allow engine to cool down completely before
proceeding with the following checks:

a. Check coolant level and replenish if low. Look

for possible coolant leakage points and repair if
necessary.

ACTION

4.

PRE LO OIL PRES lamp lights. Engine

continues to operate.

5. LO OIL PRES lamp lights. Engine shuts
down.

NOTE: See also step 6.

b. Check for obstructions to cooling airflow and

correct as necessary.

c. Check for a slipping fan belt and tighten if loose.

d.

Reset control and restart after locating and cor-

recting problem. Contact an authorized service

center if none of the above.

4.

Indicates engine oil pressure has dropped to 20 psi

(138 kPa). If generator is powering critical loads and
cannot be shut
and then follow step 5 procedure. If engine can be
stopped,

5. Indicates engine oil pressure has dropped to 14 psi
(97kPa).
is OK but oil level is low, replenish. Reset control and
restart. Contact an authorized service center if oil
pressure is 20 psi (138 kPa) or lower.

follow procedures in step 5.

Check

down,

oil

level,

wait until next shutdown period

lines

and

filters.

If oil system

8-2

TABLE

8-1.

TROUBLESHOOTING

(continued)

IAWARNINGI Many troubleshooting

procedures present hazards which

Injuryordeath. Only qualified service personnel with

hazards

6. OVERCRANK lamp lights and engine

7. Engine mns and then shuts down,

should perform

SYMPTOM

stops cranking.
or

Engine mns, shuts down, and LO OIL
PRES lamp lights..

OVERSPEED lamp lights.

service procedures. Review

6. Indicates possible fuel system problem.
a. Check for loss of engine prime, empty fuel tank,

fuel leaks, or plugged fuel lines and correct as

required.

b. Check for dirty fuel filter and replace if necessary

(see Maintenance section).

c. Check for dirty or plugged air filter and replace if

necessary (see Maintenance section).

d.

Reset the control and restart after correcting the

problem.

for service if none of the above.

7. Indicates engine has exceeded normal operating
speed.
service.

can

result

knowledge

safety

CORRECTIVE

Contact an authorized service center

Contact an authorized service center for

of

fuels, electricity,

precautions

ACTION

on

In

severe personal

and machinery

pages III and

iv.

*8.

SWITCH OFF lamp flashes.

*9.

LO FUEL lamp lights. Engine continues

to mn.

*10.LO FUEL LAMP lights. Engine shuts

down and LO OIL PRES lamp lights.

•11.

LO ENG TEMP lamp lights. Set is in

standby mode but is not operating.
(Lamp lights when engine coolant

perature is 70° F
the lamp goes out after the engine
warms up, there should be no cause for

alarm even during initial generator set

operation.)

*12-Ught Control Only.

(210 C) or lower. Since

tem-

8. Indicates Run/Stop/Remote switch is in the Stop po­sition which will prevent automatic starting if
matic transfer switch is used. Move the Run/Stop/
Remote switch to the Remote position for automatic
starting.

9. Indicates diesel fuel supply is mnning low. Check
fuel supply and replenish as required.

10.

Indicates engine has mn out of

and replenish as required.

11.

Indicates engine coolant heater is not operating, is

not circulating coolant, or ambient temperature has
exceeded capability of heater. Check for the follow­ing conditions:

a. Coolant heater not connected to power supply.

Check for blown fuse or disconnected heater

cord and correct as required.

b. Check for low coolant level and replenish if re-

quired.
and repair as required.

c. Contact an authorized service center if none of

the above.

Look for possible coolant leakage points

fuel.

Check fuel level

an

auto-

8-3

TABLE

iAWARNING] Many troubleshooting procedures present hazards which can result In severe personal

8-1.

TROUBLESHOOTING (continued)

injury or death. Only qualified service personnel with knowledge of fuels, electricity, and machinery
hazards should perform service procedures. Review safety precautions on pages III and Iv.

SYMPTOM

*12.

The FAULT 1 or FAULT 2 fault lamp

lights.
engine runs for several seconds and
then shuts
run.

13.

Fault lamp lights but no fault exists. En-

gine gauges show oil pressure, engine
temperature, and frequency (speed) are ,
within normal limits.

14.

Engine starts from generator control

15.

Engine will not crank.

Engine shuts down immediately,

down,

panel but will not start automatically or
from a remote panel. (Note: The Run/
Stop/Remote switch must be in the Re-

mote position for automatic or remote

starting).

or engine continues to

CORRECTIVE

12.

The standard undesignated fault functions are pro-

grammed to shut down the set when a fault is sensed.

Fault 1 is time delayed while Fault 2 is immediate.
The nature of the fault is an optional selection that is
determined when the set installation is designed.
The undesignated fault functions may also be pro­grammed for non-shutdown or non-time delay.

13.'

The monitor board or a sensor may be at fault.

tact an authorized service center for service.

14.

Remote circuit breaker is

restart. Contact an authorized service center if
breaker trips after resetting.

15.

Indicates possible fault with control or starting sys-

tem.

Check for the following conditions:

ACTION

tripped.

Reset breaker and

Con-

16.

No AC output voltage.

17.

Green RUN lamp does not light follow-

ing engine startup.

* 12-Light Panel Only.

a. Fault lamp on. Correct fault and reset control.
b. Poor battery cable connections. Clean the bat-

tery cable terminals and tighten all connections.

c. Discharged or defective battery. Recharge or

replace the battery.

d.

Emergency stop button (if equipped) pushed m.

To reset, pull switch put and move Run/Stop/Re­mote switch to Stop position. Then push test
switch to Reset/ Lamp position.

e. Contact an authorized service center if none of

the above.

16.

Reid breaker is tripped. Reset breaker. Contact an

authorized service center if voltage buildup causes

breaker to trip.

17.

Indicates possible Start/Disconnect relay failure.

Contact an authorized service center for assistance.

8-4

9.

Maintenance

GENERAL

Establish a maintenance/service schedule based
on

the

type

of

application,

environment

service intervals. In extreme operating conditions,
reduce the service intervals accordingly. Factors

that affect the maintenance schedule include the

following:

• Use for continuous duty (prime power)

• Extremes in ambient temperature

• Exposure to elements

• Exposure to salt water

• Exposure to windblown dust or sand

Consult
is subject to extreme operating conditions, and de­termine a suitable maintenance

all service at the time period indicated, or after the
number of operating hours indicated, whichever
comes first. Use Table 9-1 to determine the re­quired maintenance. Refer
tenance procedures.

The

Table

with

an authorized service center if the set

and

9-1

on the severity of the

lists

the

recommended

schedule.

to

this

section for

Perform

main-

IACAUTIONI Always disconnect a battery

charger
ing the battery
ing
enough to damage the

set.

IAWARNINGI Accidental

set while
sonal injury or
ing
(negative

Arcing can Ignite the explosive hydrogen gas

given off by
Injury.

tery cable Is

connect or

cable accidentally touches the frame or other

grounded

ing, always remove the
and

from

Its AC source before

cables. Otherwise,

the cables can result In voltage spikes

DC control

starting

working

by

disconnecting

[-]

first).

batteries, causing severe personal

Arcing can occur If

connected and a tool being

disconnect

metal part of

reconnect

on It can cause severe per-

death.

It last

Prevent

the starting battery cables

the

the positive (+) battery

the set. To

negative

disconnect-

disconnect-

circuits

of

the generator

accidental

negative (-) bat-

used to

prevent arc-

(-) cable first,

high

of the

start-

9-1

TABLE

9-1. MAINTENANCE

SCHEDULE

HOURS OF OPERATION

8

50

too

200
500

MAINTENANCE TASK

• Inspect exhaust system

• Inspect generator set

• Check

• Check oil level

• See

• Check air cleaner; See

.. • Change crankcase oil

Clean

• Change crankcase oil (or annually); See

. • Clean sediment

pump; See

>

*r Replace oil

• Check

• Clean crankcase breather

• Check start-disconnect circuit

• Check valve

• Clean crankcase breather

fuel

supply; See

Note

2

governor linkage

bowl

Note

1

filter

battery

condition

clearances;

Note

1

Note

3

after

first 50 hours

and

filter

See

tube

on

Note

fuel

4

Note

3

transfer

600

1500

2000

3000

5000

1.

Water

2. Tighten head bolts and adjust valve clearance

3. Perform more

4. Contact an authorized

5. Check yearly on non-commercial

or

foreign

shows

water or
should
be replaced

overhauled

be

material

excessive

checked

following

engines,

often

arid

situation

correction of

and

in extremely dusty conditions.

service

• Change primary

• Check torsional washers for corrosion; See
NoteS

• Grind valves (if required); See
Ctiebk nozzle spray pattern; See
Cleian generator

• Change sedondary

• General overhaul (if required); See

in

fuel

can ruin the injection

dirt

in

then

adjust valve

center for

sediment

corrected:

fuel

sets.

bowl,

Primary

contamination problem.

clearance

service.

fuel

filter

Note

fuel

filter

system.

fuel

handling

and

after

first 50 hours on new and

each

If daily inspection

and

storing facilities

secondary

500

hours

fuel

4

Note

4

Note

4

filters

can

thereafter.

9-2

GENERATOR

During operation,

that could create unsafe

Section
should

6 of

this manual covers

be

frequently inspected

be

SET

alert

INSPECTION

for

mechanical problems

or

hazardous conditions.

the

areas that

for

continued safe

operation.

LUBRICATION

The engine

oil was

drained from
fore shipment. Before the initial
system must
classification

section

be

filled with

and

for

the lubricating

viscosity. Referto Specifications

SYSTEM

the

start,

oil of the

oil

capacity.

crankcase

be-

the lubrication

recommended

Oil Recommendations
The

use of

with appropriate

are critical factors
ance

quality engine lubricating oils combined

oil

drain

and

filter change intervals

in

maintaining engine perform-

and

durability.

Use SAE 15W40 oil that meets the American Petro­leum Institute

or

CE/SG.

(API)

Table

Classification CC/CD, CD/SG

9-2

shows the preferred

oil

grades

for ambient temperatures indicated.

climates, refer

mendations

IACAUTIONI Limited

such

as

10W-30 may be used

to

Table

for

extreme climates.

9-2 for oil

use of low

viscosity recom-

viscosity oils,

for

easier starting
and providing sufficient oil flow at ambient tem­peratures below

ous

use of low

gine life

due to

23>

Ff-P C).

viscosity oils

However, continu-

can

decrease

en-

wean Referto the accompanying

chart.

In extremely dusty

or

dirty conditions,

oil

should

be
changed more frequently. When adding oil between
changes,
gine.

use the

same brand

Various brands

as

already

of oil may not be

in the en-

compatible

when mixed.

TABLE 9-2.

OIL

VISCOSITY/TEMPERATURE

CHART

SOW

llllll

15W40

10W30,10W40

rrrr

CC/CD
where CE

interval must
given In

The use
found

or

CD/SG engine oils

oil Is not yet

be

reduced

the

Maintenance Schedule.

of a

multi-viscosity lubricating

to

improve

oil

consumption control

prove engine cranking

maintaining lubrication

tures.

While 15W-40

can be

available,

to one

used

but the oil

half

the

oil

in

cold temperatures while

at

high operating tempera-

oil is

recommended

in

areas

change

Interval

has been

and im-

for

most

0

F-30-20-10

0

C-34

-29

-23

TTT

5W30

0 10 20 30 40 50 60 70 80 90

-18

-12

32

-7 -1 4 10 16 21 27 32 38 43 48

* PREFERRED SUMMER

100110120

9-3

Engine

L

oil level below

mark. Overfilling

of the oil while

Oil

CAUTION

Level

l

Do not

the

operation

operate

LOW

mark

the

engine

or above

can cause foaming

below the ADD mark

with the

the FULL

or aeration

can cause loss of oil pressure.

Check the engine oil level during engine shutdown

periods at the intervals specified in the Mainte-

nance Schedule. The oil dipstick and oil fill are lo­cated on the side of the engine (Figure 9-1). The
dipstick is stamped with FULL and LOW to indicate
the level of

ings,

shut off

minutes

oil

in the crankcase. For accurate read-

the

engine and wait approximately 10

before

checking

the

oil

level.

This

allows oil

in the upper portion of the engine to drain back into

the crankcase. • ,

ALWAYS REPLACE CAP

TIGHTLY OR OIL

LEAKAGE MAY OCCUR

CAP AND OIL

LEVEL INDICATOR

CRANKCASE OIL

FULL / AT THIS LEVEL

NEVER OPERATE
ENGINE WITH OIL

OIL FILL

TUBE

BELOW THIS LEVEL

KEEP

Keep the oil level as near as possible to the FULL
mark on the

dipstick.

Remove

the

oil

fill

cap

and

add

oil of the same quality and brand when necessary.

FIGURE

9-1. OIL

LEVEL

LS11S1

INDICATOR

9-4

Oil

Change

IAWARNINGI Hot

If It

Is spilled

and hands clear

plug and wear

crankcase oil can cause burns

or

splashed on skln. Keep fingers

when

removing the oil drain

protective clothing.

Change the oil and filter at the intervals recom-

mended in the Maintenance Schedule.

IAWARNINGI Used

fied by

some state

engine

or

oils

federal agencies

have

been Identi-

as

caus­ing cancer or reproductive toxicity. When
checking

to

Ingest, breathe the fumes,

or

changing

engine

oil,

take care not

or contact used oil.

Check the oil level indicator after every 8 hours of

operation,

and maintain the oil level at the FULL
mark (Rgure 9-3). Refer to the Specifications sec­tion for crankcase and filter capacity.

Oil Filter

Change

Stop the engine and drain the crankcase oil while

the engine 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, re-

place the drain plug or close the drain valve. Re­place oil filter if necessary before adding oil.

Refill

with

oil

of

the

correct

API

designation

and

SAE
viscosity grade forthe temperature conditions (refer
to Table 9-2).

IAWARNINGI Hot

If It

Is spilled

crankcase

or

splashed

oil

can cause

on

skln.

Keep

burns

fingers
and hands clear when removing the oil drain
plug and wear protective

Place

a container under the

clothing.

oil

filter and remove the

filter by turning it counterclockwise. Clean the filter

mounting area. Coat the oil filter gasket with clean

oil.

To install the new

filter,

turn the fitter on clock­wise until the gasket touches the mounting base,
then tighten 1/2 tum.

9-5

FUEL

SYSTEM

Use only high-quality fuel in this generatorset. Fuel
quality is important in obtaining dependable per­formance and satisfactory engine
clean,

completely distilled, well refined, and non-

life.

Fuel must be

corrosive to fuel system parts.

IAWARNINGI Ignition of fuel can cause severe

personal Injury or death by fire or explosion. Do
not permit any flame, cigarette, spark, pilot
light, arcing equipment or other Igniter near the
fuel system.

Fuel Recommendations
Use ASTM 2-D (No. 2 Diesel) or ASTM 1 -D (No. 1

Diesel) fuel with a minimum Cetane number of 45.
Number 2 diesel fuel gives the best economy and
performance under most operating conditions. Use
number 1 diesel fuel when ambient temperatures

are below 0° C (32°
engine

load.

F),

or during long periods of light

The fuel's viscosity must be kept above 1.3 cSt to
provide adequate fuel system lubrication.

temperature. (Cloud point is the temperature at

which wax crystals begin to form in diesel fuel.)

Fuel

Handling Precautions

Take appropriate precautions to prevent the en-

trance of dirt, water or other contaminants into the

fuel system. Filter or strain the fuel as the tank is

filled.

IACAUTIONI Due to the precise tolerances of die-

sel Injection systems, dirt or water In the fuel
can cause severe damage to both the Injection

pump and Injector nozzles. Take special pre-

cautions

to

keep the fuel clean and free of water.

To avoid condensation problems, keep fuel tanks as
full as possible. In cold weather,>warm fuel return-

ing from the engine heats the fuel in the supply tank,

If the fuel level is low, condensation tends to form in
the upper portion of the tank. In warm weather, the
fuel and the tank will both be warm during the day­time.

At night, cool air lowers the temperature of the

tank more rapidly than the temperature ofthe

fuel.

If
the fuel level is low, the upper portion of the tank will
cool more rapidly and condensation will tend to
form.

Fuels with Cetane numbers higher than 45 may be
needed In higher altitudes or when extremely low
ambient temperatures are encountered to prevent
misfires and resultant excessive smoke.

Use low-sulfur-content fuel with a cloud point at
least 10 degrees below the lowest expected fuel

Condensation (water) can clog fuel filters as well as
causing freezing problems. Also, water mixing with
the sulfur in the ftiel forms acid which can corrode
and damage engine parts.

9-6

Fuel

Filters

The filters are
drain is situated at the bottom ofthe filter case

spin-off,

throw-away units. A water

(Fig-

ure 9-2). This should be used to drain off moisture

either daily or at the end of every exercise period,

depending on unit application.
The drain plug on the fuel filter can tolerate only a

limited amount of torque.

Use

two wrenches in com-

bination for breaking the plug loose and for final

tightening.

Change the primary and secondary fuel filters at the
intervals recommended in the Maintenance Sched­ule.

Change the fuel filters by removing the washer

and capscrew on top of the fuel filter body.

CONNECTOR

(FROM FUEL

TRANSFER PUMP)

PRIMARY

FILTER

DRAIN

ELBOW (TO

INJECTION PUMP)

SECONDARY

FILTER

DRAIN

FS1113

Fuel

Pump Sediment Bowl

Remove the sediment bowl from the fuel filter body
(Figure

9-3).

Clean out any contaminants from

sedi­ment bowl. When re-installing the sediment bowl,
make sure that gasket and screen are in place.

FIGURE

FUEL PUMP AND

FILTER BODY

GASKET-

9-2. DUAL

FILTER

BOWL.

FUEL FILTERS

9-7

FIGURE

9-3.

FUEL

PUMP

SEDIMENT

FS1115

BOWL

Priming the

Fuel

System

4.

Tighten the fuel line at the injection pump inlet.

The fuel system must be primed before initial
startup or afterthe engine has run out of

fuel.

Prime

the fuel system as follows.

1.

Check fuel level in fuel tank and open shutoff

valve.

2.

Loosen the fuel filter-to-injection pump line at

the injection pump fuel inlet fitting (Figure 9-4).

3. Actuate the hand priming lever on the fuel
transfer pump until the fuel flows from the fit­ting.

If the pump lobe of the camshaft is up (no re­striction can be felt when moving priming le­ver),

crank the engine one revolution to permit

hand priming:

ALWAYS RETURN

PRIMER LEVER TO

LOWEST POSITION

5. Actuate the hand priming lever several more
times to prime the injection pump.

6. When finished, retum priming lever inward
(disengaged position) to permit normal pump

operation.

WORK TRANSFER PUMP PRIMING

LEVER UNTIL FUEL FLOWS FROM

FUEL INLET FITTING

FIGURE

9-4.

FUEL

SYSTEM

FUEL INLET FITTING

TO INJECTION PUMP

FUEL

RETURN;

LINE

FS1777

9-8

AIR CLEANERS

IACAUTIONI

to prevent

Filters should

damage.

If the filter

be

handled with

does

care

become

damaged. Install recommended replacement

part

After every

50

hours of

operation,

remove

and

clean
the filter element (Figure 9-5). After washing the
element

in

solvent,

dip the

element

in

engine

oil

and

squeeze it as dry as possible.

CONTRACTOR

1.

Remove

pre-cleaner

MODEL AIR

(Figure

9-6)

CLEANER

and

wash

out

dirt. Dry and reinstall.

2.

Loosen clamp and remove end cover.

3. Remove thumbscrew and take out element.
Wash

element

element after 6

4.

Remove

in

detergent

washings).

air cleaner

baffle

and

water

(use

Dry and reinstall.

from

cover,

wash

new

out

dirt, and reinstall in cover.

5. Install cover

with

"TOP" up and tighten clamp.

ELEMENT

HGURE

COVER

9-5.

POLYURETHANE

CLEANER

DUST

THUMBSCREW

\_

CLAMP

RETAINER

FOAM

(PRE-CLEANER)

^

AIR

CUP

HI 770

9-9

HGURE

FS18S3C

9-6. CONTRACTOR MODEL AIR

CLEANER

GOVERNOR

LINKAGE

Every 100
nor ball joints apart

these

IACAUTIONI Some solvents can damage the

neoprene governor ball joints. Read the
facturer's
lubricants or

hours,

carefully

and

joints.

See Figure 9-7.

recommendations

solvents

pull

clean

near

the neoprene gover-

them.

Do not lubricate

manu-

before using any

the

ball joints.

FIGURE

9-7. GOVERNOR

CLEAN

BALL

BALL

JOINT

*FS1114

JOINT

BATTERIES

IAWARNINGI Ignition of explosive battery gases

can cause severe personal Injury. Do not
smoke or allow any source of Ignition while
servicing batteries.

Check the condition ofthe starting battery at the in­terval specified in the maintenance schedule. To
prevent dangerous arcing, always disconnect the
negative ground strap from the battery before work­ing on any part of the electrical system or the en­gine.

Disregard the sections on Checking Specific
Gravity and Checking Electrolyte Level if using a
"maintenance-free" battery.

Be sure the vent plugs are tight to prevent cleaning
solution from entering the cells.

After cleaning, flush the outside of the battery and
surrounding areas with clean water.

Keep the battery terminals clean and tight. After
making connections, coat the terminals with a light
application of petroleum jelly or non-conductive
grease to retard corrosion.

Checking

Specific

Gravity

Use a battery hydrometer to check the specific

gravity of the electrolyte in each battery

cell.

IAWARNINGI Arcing can Ignite the explosive hy-

drogen gas given off by batteries, causing se-

vere personal Injury. Arcing can occur If the
negative (-) battery cable Is connected and a
tool being used to connect or disconnect the

positive (+) battery cable accidentally touches

the frame or other grounded metal part of the
set. To prevent arcing, always remove the nega­tive (-) cable first, and reconnect It last.

IACAUTIONI Always disconnect a battery

charger from Its AC source before disconnect­ing the battery cables. Otherwise, disconnect­ing the cables can result In voltage spikes high
enough to damage the DC control circuits ofthe
set.

Cleaning

Batteries

Keep the batteries clean by wiping them with a

damp cloth whenever dirt appears excessive.

If corrosion is present around the terminal connec-

tions,

remove battery cables and wash the termi­nals with an ammonia solution or a solution consist­ing of 1/4 pound of baking soda added to 1 quart of
water.

Hold the hydrometer vertical and take the reading.
Correct the reading by adding four gravity points
(0.004) for every ten degrees the electrolyte
perature is above 80° F (27°

C).

A fully charged bat­tery will have a corrected specific gravity of
Charge the battery if the reading is below

Checking

IACAUTIONI DO not add water In freezing

Electrolyte

Level

tem-

1.260.

1.215.

weather unless the engine will run long enough

(two to three hours) to assure a thorough mix-

ing of water and electrolyte.

Check the level of the electrolyte (acid and water
solution) in the batteries at least every 200 hours of
operation.

Fill

the battery cells to the bottom ofthe filler neck, if
cells are low on water, add distilled water and re­charge. If one cell is low, check case for leaks.
Keep the battery case clean and dry. An accumula­tion of moisture will lead to a more rapid discharge
and battery failure.

9-11

CRANKCASE BREATHER

Clean the crankcase breather at the intervals rec-

ommended in the Maintenance Schedule.

BREATHER

HOSE

To clean the crankcase breather, remove hose
clamp, breather

hose,

breather

cap

clamp

and

insu-

lator halves to release breather cap and valve as-

sembly (Figure

9-8).

Wash

cap,

valve assembly and

baffle in suitable solvent. Dry and reinstall.

CRANKCASE BREATHER TUBE

Clean the crankcase breather tube at the intervals
recommended in the Maintenance Schedule.

To

clean the crankcase breather
rocker covers (Figure
is installed with a sealant

9-9).

on

tube,

remove both

The breather tube itself

the threads to prevent

oil leakage into the intake manifold; it should NOT

be removed. 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 also be removed at that time.

c

HOSE CLAMP_

CAP AND VALVE.

O-RING

FILTER

BREATHER

TUBE

FIGURE 9-8. CRANKCASE BREATHER

CLEAN CRANKCASE

BREATHER PIPE

EVERY 500 HOURS

SCREEN

RETAINER

CLAMP

OIL BAFFLE

ASSEMBLY

LS1206C

CRANKCASE

BREATHER

TUBE

9-42

cion

FIGURE 9-9. CLEANING BREATHER

Four

TORSIONAL

torsional

washer assemblies are bolted inside

WASHERS

the flywheel pulley hub (Figure 9-10). When func­tioning properly, they react to relieve torsion

stresses on the crankshaft. Inspect the assemblies
periodically for movement of washers and freedom
from corrosion (1500 hours commercial, yearly
non-commercial): If condition is questionable,

con-

tact an Onan service center or distributor.

FIGURE

9-10. TORSION

WASHER

ASSEMBLY

9-13

OUT-OF-SERVICE

The inherent lubricating qualities of
normally should protect the cylinders of a diesel en­gine for at least 30 days when the unit is not in serv­ice.

To protect an engine that will be out of service

for more than 30 days, proceed as follows:

1.

Exercise the generator set as described in the

Operation section until the engine is up to oper-

ating temperature.

2.

Shut down the engine. Disconnect battery and

store in a
charger every 30 days to maintain it at full
charge.

3. Drain the oil base while it is still warm. Refill
and attach a waming tag indicating the viscos-,
ity of oil used. - ' „

•

4. Service the-air cleaner.' ' , -

5. Clean throttle and governor linkage and protect
by wrapping with a clean cloth.

6. Plug the intake and exhaust outlets to prevent
entrance of moisture, bugs, dirt, etc.

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

8. Provide a suitable cover for the enti re unit after
unit has cooled down.

cool,

dry place. Connect battery to a

PROTECTION

No.

2 diesei fuel

oil.

RETURNING A UNIT

1.

Remove the cover and all protective wrapping.

Remove the plug from the intake and exhaust

outlet.

2.

Check the warning tag on the oil base and ver-

ify that the oil viscosity is still correct for the ex­isting ambient temperature.

3. Clean cooling fin areas.

4.

Clean and check the battery. Measure the spe-

cific gravity (1.260 at 80° F [27° C]) and verify
that the level is at the split
gravity is low, charge until the correct value is
obtained.
and charge until the specific gravity is correct.

DO NOT OVERCHARGE.

- IAWARNINGI Ignition of explosive battery
gases can cause severe personal Injury. Do

^ pot smoke or allow any Ignition source

while servicing batteries.

5. Connect the starting battery (ground terminal
last).

6. Prime the fuel system.

7. Remove all loads before starting the engine.

8. Start engine and observe oil pressure gauge
and charge rate ammeter.

9. After start, apply load to at least 50 percent of
rated capacity.

10.

Unit is ready for service and load may be ap-

plied.

Ifthe level is low, add distilled water

TO

SERVICE

ring.

If the specific

,

10.

Maintenance

Record

Keep a record of all periodic and unscheduled
maintenance. Record the service date and the
number of operating hours from the hour

DATE

HOUR

METER

READING

meter.

Referto the Maintenance Schedule in Section 8 for

the

time

interval between maintenance procedures.

Record

center and keep all of your service receipts.

SERVICE

the

name

PERFORMED / NOTES

and

address of your Onan service

Record the name, address, and phone number of

your authorized Onan service center.

10-1

11.

Wiring

GENERAL • Page 11-3-Customer Connections at the En-

Diagrams

gine Monitor Board.

This section consists ofthe schematic

tion

wiring diagrams

lowing drawings are

referenced

included.

in the

• Page 11-5-Generator Reconnection Diagram

and

connec- • Page

text. The

fol- •

11

-4-Customer Connections at the Aux-

liary Relay Board

-

11-1

TB1-10 (SWfTCHED B+ OUTPUT) OUTPUT TO RELAY K12, FUSED AT 20 AMPS, ENERGIZED WHEN THE

START SIGNAL IS APPLIED AND DE-ENERGIZED AT SHUTDOWN (NORMAL AND FAULT)

TBI-9 (B+ INPUT) BATTERY POSITIVE (+) CONNECTION

TB1-8 (START SOLENOID) OUTPUT TO RELAY

K11,

FUSED AT 20 AMPS

TBI-7 (B+ OUTPUT) OUTPUT TO TIME DELAY START/STOP MODULE Al 5,

FUSED AT 15 AMPS, AVAILABLE WHEN THE STARTING BATTERIES ARE CONNECTED

TB1-6 (REMOTE START) CONNECTED TO TIME DELAY START/STOP MODULE A15. CONNECT REMOTE START

CONTACT OF THE AUTOMATIC TRANSFER SWITCH TO TERMINAL

TB1

-5 OF MODULE A15.

TB1-5

(GROUND)

TB1-4 (COMMON ALARM B+ OUTPUT) 4 AMP RATED DEVICE MAXIMUM

TBI-3 (RUN) CONNECTED TO TIME DELAY START/STOP MODULE A15

TBI-2 (DC DISCONNECT) CONNECTED TO TIME DELAY START/STOP MODULE Al

5

5*

COKTROL

R

Ul

C8

C3

• R9
I

1

U3

U5

—

VR2

KB

K7

R10

cne

-

CR17

•1

U2

DBD

iq

CR9

C5

C7

Kll

a

CRB

CRG

+

ID

5:

LJ

H

(Zl

a CRIB

KIG

W4

rj

n

CRI a

um um

Wl

Kl K5

CRI?

CRI?

LJ

"l

g 3 1 5 6 7 8 ~9~ IB 15 H H 15 IB

CR3

^

™ I

CR5

CREB

VR3

KIB

KB Kll K13 K15

L_l

I

CR13

dl

K]2

RB
R7
RG

_n_

I

3

W

WG

W7

Dffl

KIB

K17

15 13

K22

•1

CRII CRIE

K19

CD

LJ

Lu

F5

A

•

US

9
IB
II
12

1
5
3
4
5
6

7

P3

8
9

IB
li

15

PA

THIS

IS A

REPRESENTATIVE
SCHEMATIC/WIRING
TROUBLESHOOTING,

IWIRING

•NCLUDED

DIAGRAM

WITH

PACKAGE

YOUR

TB2-10 (PRE-HIGH ENGINE TEMPERATURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*

(GENERIC)

DIAGRAM. FOR

REFER

TO

THE

THAT WAS

GENSET.

TB2-1 (FAULT 2) GROUND INPUT FROM SENDER

TB2-2 (FAULT 2) GROUND OUTPUT TO LIGHT/RELAY*

TB2-3 (FAULT 1) GROUND INPUT FROM SENDER

TB2-4 (FAULT 1) GROUND OUTPUT TO LIGHT/RELAY*

TB2-5 (REMOTE RESET) MOMENTARY CONTACT TO GROUND

TB2-6 (OVERCRANK FAULT) GROUND OUTPUT TO LIGHT/RELAY*

TB2-7 (OVERSPEED FAULT) GROUND OUTPUT TO LIGHT/RELAY*

TB2-8 (HIGH ENGINE TEMPERATURE FAULT) GROUND OUTPUT TO LIGHT/RELAY*

TB2-9 (LOW OIL PRESSURE FAULT) GROUND OUTPUT TO LIGHT/RELAY*

TB2-11 (PRE-LOW OIL PRESSURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*

TB2-12 (SWITCH OFF WARNING) GROUND OUTPUT TO LIGHT/RELAY*

TB2-13 (LOW ENGINE TEMPERATURE WARNING) GROUND OUTPUT TO LIGHT/RELAY*

TB2-14 (LOW FUEL WARNING) GROUND INPUT FROM SENDER

CUSTOMER

* 0.5 AMP

SUPPLIED

FACTORY

RATED

DEVICE

P2

WIRING

WIRING

MAXIMUM

TB2-16 (EMERGENCY SHUT DOWN) MOMENTARY CONTACT TO GROUND

CUSTOMER

TB2-15 (LOW FUEL WARNING) GROUND OUTPUT TO LIGHT/RELAY*

CONNECTIONS AT THE

ENGINE

MONITOR

BOARD

11-3

TB2

9

RUN

3

N/C

_

j_

<2

N/O

N/C

._L.

9

COMMON
ALARM

N/O I N/C N/O

9 9

9

H/O

NA:

._3..

9 9

N/O

H/C

._L.

._L.

9 9 9

p

3

ISOLATED

N/C N/O

._3..

N/O

._3._.

9 i

mi-TBi-io

All-TBI-4

AII-IBI-5

HII-IBI-7

Aii-iai-6

AU-1B1-3

All-TBZ-11
AII-TB2-10

a b*

COn

cm

ISA B«

mr

START

HH

PIOLOP

PRETCT

SPflRE

J2r.

I I

n

TB!

r 1

94 I

su

I

con

ALMHI

RUN

1

isn Bt

RNT

START

TBG con N/C N/O

r
! 9 9 9

K4.2

K<.

ttl — .

4

2

1

TB3

6 o

con

i

9

K5.2

K5.

I

4^

con

2

o 9 9

KS.2

K6.

con

3

1

O

N/O

9-

9

Wl 1

K7.
SfLL

4^

k'2

1

/Ts /T\

f

COM

3

9

O

Q

N/C

o

_

6

con

2

o o

om

i

N/C

:

Q

9

Cil

o

9

W12

T

o i

TB7 con

7

r

sa*-

K9.2

2

9

2

W3

/T\

/t\ /K

• o

t

TBS

G

4J"

COM

I

0. 9

8 _t

con

Q

-lie

B

O

cm

3

9 9

con
O

W13

i4

• t

9

Q

2

K15.2

Q

9

•

4¥P

K9.

1

1

L

CH-

4>

4}

1

A1I-TB2-3
All-TBZ-B
A1I-TB2-7
AII-TB2-6
AII-TB2-1
AII-IB2-2
AI1-TB2-I3
AII-TB2-IS
AII-TB2-I2

LOP
ICT
OS
OC

FLT I

TLT 2

LET
LO FUL
SM OFF

Jl

I 1
I

THE

TERMINALS

IN THE SHADED

BOXES

ARE

FOR CUSTOMER CONNECTIONS

CUSTOMER

CONNECTIONS AT THE AUXILIARY

11-4

RELAY

THIS

IS A

REPRESENTATIVE
SCHEMATIC/WIRING
TROUBLESHOOTING,

WIRING

INCLUDED

DIAGRAM

WITH

PACKAGE

YOUR

BOARD

(GENERIC)

DIAGRAM.

REFER

TO THE

THAT

GENSET.

FOR

WAS

3 PHASE RECONNECTABLE,

12

LEAD

YD

GENERATORS

I PHASE RECONNECTABLE,

12

LEAD

THIS

IS A REPRESENTATIVE
SCHEMATIC/WIRING
TROUBLESHOOTING,
WIRING DIAGRAM
INCLUDED

WITH

PACKAGE

YOUR

(GENERIC)

DIAGRAM. FOR

REFER

TO THE
THAT WAS

GENSET.

60HZ

•SOHZ

60HZ

SOHZ

—

—

—

—

SECONDARY CURRENT TRANSFORMER CONN.

I20/240V.

IP0/200V, V4-VI
II0/220V, V4-VI
II5/230V. V4-V2
I20/240V, V4-V3

120V, V4-VI

V4-VI

I

PHASE

SECONDARY CURRENT TRANSFORMER CONN.

L

T3

8

L4

IOOV. V4-VI
IIOV, V4-VI
I

15V.

V4-V2

120V. V4-V3

RECONNECTABLE, 4 LEAD

1-3

I20/240V.

I

ttJl

tfl

I00/200V, V4-VI
II0/220V. V4-VI
II5/230V. V4-V2
I20/240V, V4-V3

1-3

I20/208V,
I27/220V.
I39/240V,

I IO/l90V, V4-VI
II5/220V, V4-V2
I20/208V. V4-V3
I27/220V, V4-V4

V4-VI

V4-VI
V4-V2
V4-V/t

CT2I

Ll

LO

L4

—

60HZ

- SOHZ

SECONDARY CURRENT TRANSFORMER CONN.

240/416V, V4-VI
254/440V, V4-V2
277/480V, V4-V4

220/380V, V4-VI
230/400V, V4-V2
240/416V. V4-V3
254/440V, V4-V4

VOLTAGE
CONTROL

1-2

INPUT

TB2I

-21

-23

-24

-25

-26

SENSING

GENERATOR

SENSING

LEADS

8
7
4
6 6
5 5

CONTINUITY

347/600
CONNECT
SENSING

LEADS

TO
8
7

:-

"

SECONDARY CURRENT

TRANSFORMER CONN.

I20/240V, V4-VI

:I0/220V, V4-VI
II5/230V. V4-V2
I20/240V. V4-V3

1-3

— 60HZ

- 50HZ

NOTES:

1.

CURRENT TRANSFORMER SECONDARY

ABOVE 300 VOLTS AC,
BELOW

300 VOLTS AC,

TERMINALS

2.

DESIGNATIONS

WIRE
IN

ACCORDANCE
LEAD
VR2I-5
REGULATOR

3.

WHEN

INSTALLED
JUMPER

4.

GENERATOR VOLTAGE

CONNECTED

2/3

ARE COMMON AND

V4-VI.-V2

ON

VOLTAGE REGULATOR,

FROM

FOR

WITH

XI-I

OUTPUT VOLTAGE

MUST

SOHZ. THESE

ONLY.

300-0688

IS REMOVED

SWITCHING

ON

VR2I

BETWEEN

FOR 60 HZ.

SENSING

TO

GENERATOR OUTPUT LEADS
AND VOLTAGE REGUALATOR
LIEU

OF

MARKING

AS

FOLLOWS:
GEN-4
GEN-5
GEN-6 RED/BLK
GEN-7
GEN-8

INSULATE

AND

347/600V

SECONDARY CURRENT TRANSFORMER CONN, i-2

MUST

BE
TERMINALS I & 2
TERMINALS I &,

CONNECTED

OR -V3

BE

RECONNECTED

INDICATE

VR2I.

JUMPER

INSTRUCTIONS

MANUALLY

;

3.
TO

CONNECTION

AND

FREQUENCY.

TO

VR2I-6

APPLY

GROUND.

MUST

TO

REGUALTOR IS USED. A JUMPER

TBI-7

LEADS

AND

TBI-8

FOR

GEN-4,-5,-6,-7, &,

AS SHOWN FOR

OPERATION.

LT

GRN/BLK

LEADS

MAY BE

TAN/BLK
YEL/BLK

DK

BLU/BLK

TIE

BACK

ANY

UNUSED

LEADS.

V4-VI

60HZ

SELECTED:

OF

BE

JUMPER

CONNECTED

ALSO.

FOR

60HZ

300-1540

IS

SOHZ.

THIS

-8

MUST

PROPER

COLOR CODED IN

NO.
REV.
MODIFIED 12/1/93

THE

OR

BE

METERING

625-2758 1 ot 1

A

RECONNECTION

11-5

DIAGRAMS