McGraw-Edison Onan GenSet 3.ORDJA User manual

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SAFETY PRECAUTIONS
Thefollowingsymbolsinthismanualsignalpoten-
tiallydangerousconditionstotheoperatororequip-
ment.Readthismanualcarefully.Knowwhenthese
conditionscanexist.Then,takenecessarystepsto
protectpersonnelaswellasequipment.
WARNING I Onan'uses this symbol
* throughout this manual to
warn of possible serious personal injury.
This symbol refers to possible
equipment damage.
Donotworkonthisequipmentwhenmentallyor
physicallyfatigued.' .
Fuels, electricalequipment,batteries,exhaustgases
andmovingpartspresentpotentialhazardsthat
couldresultinserious,personalinjury.Takecare'in
followingtheserecommendedprocedures.
••Use ExtremeCautionNear Gasoline. A constant
potentialexplosiveor fire hazard exists.
Donotfillfueltankwithenginerunning.Donot
smokeoruseopenflameneartheunitorthefuel
.; tank.,
Besureallfuelsupplieshavea positiveshutoff
valve. • -
Thefuel supply and return lines must
be routed separately, and never tiedto-
gether with any'electrical wiring. Use
aflexible .section offuelline between
,' generator compartment and stationary re-
mote fuel tank in truck chassis. This
flexible section must-be 100%NON-MET-
ALLIC to prevent electrical current
^from using itasa conductor.
• Havea fire extinguishernearby.Be sure extin-
guisher isproperlymaintainedandbefamiliar
with itsproperuse. Extinguishers ratedABCby
the NFPA areappropriateforallapplications.
• GuardAgainst Electric Shock
Disconnectelectricpowerbeforeremovingpro-
tectiveshieldsortouchingelectricalequipment.
Userubberinsulativematsplacedondrywood
platformsoverfloorsthataremetalorconcrete
whenaroundelectricalequipment.Donotwear
dampclothing(particularlywetshoes)orallow
skinsurfacestpbedampwhenhandlingelectri-
calequipment.
r ,
Jewelryisa goodconductorofelectricityand
.shouldberemovedwhenworkingonelectrical
equipment.
DONOTPLUGMOBILE,PORTABLEOR'
STANDBYSETSDIRECTLYINTOA HOUSE
RECEPTACLETOPROVIDEEMERGENCY
POWER.Itispossibleforcurrentt'oflowfrom
generatorintotheutilityline.Thiscreatesex-
tremehazardstoanyoneworkingonlinestores-
torepower.
Useextremecautionwhenworkingonelectrical
components.Highvoltagescauseinjuryordeath.
Followallstateandlocalelectricalcodes.Have
allelectricalinstallationsperformedbya quali-
fiedlicensedelectrician. •''0'»,.
• DoNotSmokeWhile Servicing Batteries
Leadacidbatteriesemita'highlyexplosive
hydrogengasthatcanbeignitedbyelectrical
arcingorbysmoking.
• Exhaust Gases Are Toxic
Provide an adequate exhaus't'system to properly
expel discharged gases. Check exhaust system
regularly for leaks. Ensure that exhaust manifold's
are secure and not warped, -x-r.
Besuretheunitiswellventilated.Don'tusedis-
chargedcoolingairforcompartmentheating'
sinceitcouldcontainpoisonousexhaustgases.
• Keep The Unit AndSurroundingArea Clean
Removealloildeposits.Removeallunnecessary
greaseandoilfromtheunit.Accumulatedgrease
andoilcancauseoverheating-andsubsequent
.enginedamageandmaypresenta potentialfire
hazard.
DoNOTstoreanythinginthegeneratorcom-
partmentsuchasoiloVgascans,oilyrags,
chains,woodenblocks,etb.-Avfirecouldresultor
thegeneratorsetoperation(cooling,noiseand
vibration)maybeadverselyaffected.Keepthe
• compartmentfloorcleananddry.
Donotsteamcleanthegeneratorsetwhilethe
engineisrunning.Whehcleaning,donotspray
directlyintothegenerator,controlbox,orair
cleaner.,
•v
: r
• ProtectAgainst Moving Parts
Avoidmovingpartsofthe'unit.Loosejackets,-
shirtsorsleevesshouldnotbewornbecauseof
thedangerofbecomingcaughtinmovingparts.
Makesureallnutsandboltsare1secure.Keep
powershieldsandguardsinposition.
Ifadjustmentsmustbemade'whiietheunitis
running, us.eextremecautionaroundhotmani-
folds, movingparts,etc.
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TITLE PAGE
SafetyPrecautionsINSIDEFRONT COVER
.IntStfiWtelR^.^?* • •••
Pre-lnstallationInstructions -
Specifications 5
Compartment DISASSEMBLY • • • 6
Compartment and GenSetInstallation(Over-The-Rail Mount)?
'.COOLING SYSTEM. • 11
Exhaust System
Fuel System •'.15
Electrical Loads and Connections
18
RemoteStartingPanelInstallation 22
ConnectingGenSet To TruckBatteries 25

^ Introduction
This manual covers detailed installation
procedures andrecommended practices for
installing the Onan 3•ORDJA diesel powered
auxiliary generator setin sin "Over-The-
Rail" configuration ONLY, fysad through
theentire manualfor familiarity prior to
actually installing this generator set.
^.Thisnanual is arranged in a logical se-
quence of steps that should be followed
when performing the actual installation.
^Theremote control,muffler and exhaust
tubing, connectors and hardware required
for installation arepackagedin an acc-
essorykit suppliedwith eachset when
shipped. DoNOT proceed with the install-
ation if any items are missing.
Any items not supplied but required to
complete the installation are specified
and recommended where'appropriatethrough-,
out themanual. Some of theseitems will
be available in Optional kit formfrom
Onan. Allotheritems specified and re-
quired should be procured locally prior
to starting the actual installation.
Thisgenerator setis shippedfrom the
factory completely assembled within the
insulated compartment housing for pro-
tection duringshipping. Some housing
panels and internal compartment wiring
require disassembly prior to installing
the generator setin placeover the truck
frame rails.
WARNING
ONAN RECOMMENDS THAT GENERATORSET
INSTALLATIONANDALLSERVICEONLYBEDONE
BY PERSONSQUALIFIEDTOPERFORM ELECTRI-
CAL AND/OR MECHANICAL SERVICE. TOPREVENT
POSSIBLE INJURY AND/OR EQUIPMENTDAMAGE
ITISIMPERATIVE THAT THESERVICEPERSONBE
QUALIFIED.
IFITISNECESSARYTORELOCATEOR MODIFY ANY
MAJORTRUCKCHASSISCOMPONENTSSUCHAS
BATTERIES, TANKS,TOOLBOXESORANYOTHER
TRUCK ACCESSORIES, ALLWORK MUST BEPER-
FORMEDBYANEXPERIENCEDTRUCKDEALEROR
SERVICE PERSONONLY.THESE CONDITIONS
MUST BEIDENTIFIEDPRIORTOPERFORMINGANY
PARTOFTHEAUXILIARYGENERATORSETIN-
STALLATION.THECOMPLETEDINSTALLATION
MUST CONFORMTOFEDERAL MOTOR CARRIER
SAFETY REGULATIONS,TITLE49,PART393AND
FOLLOWTHERECOMMENDEDPRACTICESOFTHE
AMERICANTRUCKINGASSOCIATION MAIN-
TENANCECOUNCIL.

Pre^astollgtionInstructions
PRE-INSTALLATION EVALUATION
Eachtruckchassismustbeevaluatedandcertain_
measurementsmustbemadebytheinstallerpriorto
startinganyinstallation.Thesemeasurementsde--
terminewhetherthereissufficient,unobstructed
spacetopermitinstallationofthegeneratorsetcom-~
partmenta*wjM'h»"fuol tooU. intheirrecommended
locations..
fee-Tua/Sec"hv»u.^ . _, •,,•.„•
Thegeneratorsetsaredesignedprimarilyforinstall-
ationinClass7 or8 longhaultrucks.Exactcompart-
mentmountinglocationalonothetruckframerailwill
varybetweendifferent^^fwe?itiena4-truckmakesand
models.
Incafl'-^v^rei^tfi-e*T9P^ttrucks<,for"Over-the-Rail"
installations,a locationas4^«6t-w¥pd^Sw.a«iback
walloftruckcabismostsuitableforpurposesof
betteraxleweightdistribution.SeeFigure2.
Distance"X"listedinTable1,whenmeasuringfor
installation.MUSTbemaintainedtoallowforany
truckmaneuverinordertoproceedwithanyOvar-
the-Rai! installation.Referencejiki&l&a-f+e^.when
measuringdistance"X".P.jjur-s.i_
KINGPIN
4INCHMINGENSET-TO-TRAILEB
CORNERCLEARANCE
TOPVIEWOFTRUCK
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^COMPARTMENT SIZE ANDLOCATION
•Designvariablesintruckwheelbaseandcab
stylesmayrequirerelocationofbatteries,tool
~"boxes,etc.,tomakeroomforthegeneratorset
Somedegreeofmodificationandpossiblyrelo-
catingsomeofthesechassisComponentsmaybe.
necessarytoprovidethephysicalspace(length)
requiredtoproceedwiththeinstallationofthe
generatorcompartment.
~If It Is necessary to relocate or
modify any major truck chassis
WARNING
>A minimumverticalclearanceof1/2inchmustbe
maintainedbetweenthegeneratorsethousing
baseplate(whereinstalledovertruckframerails)
andanypermanenttruckchassiscomponent
underneathgeneratorsetcompartment.Spacers
shouldnotbeusedtoobtainthisclearance..
Housingbaseplatecanbemovedhorizontallyto
obtainthisclearanceaslongasminimumspace
(23-3/4inches)isNOTreduced.Housing
baseplatemustrestontruckframerails
wheninstalledasshowninFigure3>
components such as batteries, tanks or tool
boxes or any other truck accessories, all work
must be performed by an experienced truck
dealer or service person only. These conditions
must be identified prior to performing any part ol
the auxiliary generator set installation. The
completed installation must conform to Federal
Motor Carrier Safety Regulation, Title 49. Part
393 and follow the recommended practices ofthe
American Trucking Association Maintenance
Council.
Thephysicalsize(primarilydepth)ofthe
generatorcompartmentrequiresa MININUM,
UNOBSTRUCTEDOPENSPACEof23-3/4inches
parallelto(lengthwise)thetruckframerails
directlybehindthecab.Measurealongtheframe
railsinthedesiredmountinglocationtoverify
thisspaceisavailable.SeeFigure3forminimum
over-allinstallationdimensions.
I.SO—i
(REAR HOUSING PANEL)
23.75 — -
©3.38-
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3.62
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he SI
metricequivalents are printed In parenthesisimmediatelyfollowing
theU.S.customaryunit of measure
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COMPARTMENT SIZE
Height(Without Muffler) 31-38 in. (797inm)
Width 34.00 in. (8631™)
. Depth... 0 0 23.75 in. (603mjnj
Approximateweight including compartment 560 lbs. U.54kg)
Starting System Voltage //V * * \*\12~volts
130
Battery Ground C&V'f?^ .^ffVn^. P&b'firfJj Negative Ground Standard
.Starting System c ..«. .« Motorized Alternator Cranking
CrankingCurrent 300Amperes
Break-away Current (Maximum) • . 4-75Amperes
Fuel Diesel
demote Kael Tank G-jTpacity •rv.~y<T\ ^K^-G^llonsi^J-L)
rengt-fi .\ / /../.. .\/"'\/ 2VF1' (^9mm) )
"4Vjru
V 7 ' '
.\.........V / l<5.feo in. ^393nAi)
.^in^Ci^Qsim)
^e^th . . • • rv'. •..««...••«••«. V^-^-^. • • • • ... • r>^-. ...••o.. • >-.-^-^.. • 7
Fuel Pump Mechanical
Fuel Return and Supply line ConnectionSize SAE-4 370Flare
-NOTE: Refer to auxiliary generator set Operator's manualfor completeengine-
generator specifications.
0Q. U)tV<. >• XJO orcvi^*
7#-

ment wiring, require disassembly, prior to
insialling. thegenerator seVin place over
thetruck frame rails to .simplify the
mounting plate and wiring connections to
thetruckchassi:
Proceed as follows!
1. Eemove the/cpmpartment front.cover
. •' by releasing the rubber straps on/
•top apd then-lift cover up and^out
froprietents on bottom of front
a-hel. .
Remove thetop compartment panel by
removing eight5/l6-l8/x 3/4 inch hex
head capscrews aroundrthetophousing
perimeter as shown in Figure 4.
Remove the four 5/16-18 x 3/4 inch hex
head capscrews which secure the left
side housing pdriel to the rear(back)
panel of the/compartment as shown in
Figure 4."
resu/f \l the baseplate shouiti tail oil fra.'mj ran*,
during the installation procedure.
Remove the ..four 5/16-I 8 x 3/4 inch hex
.head capscrews which secure the right
' side housingpanel tothe rear(back)
panel ofthe compartment as shown in
Figure 4.•'
NOTE: • Left/and right sides are- determined
While facing the hinged front covery.of the
generator/set. / •
/' /
4. 'Remove the two 1/4-20 x 5/8 inch hex
head capscrews on the ex'terior of the
rear(back)housing panel which secure
the compartment fan/assembly to the
rear(back)panel as/shown in Figure 4.
These, two bo Its .-are 5-7/8 inches in
(to center)from left rear corner o£
.the compartment. . yy
5. Unplug the/fan assembly AC"cord andthe
water solenoid AC cord from-theduplex
receptacle ontopof the, generator end
ofthe^setinside the^ho'using.
6. Remove the three 3/8-16 x 3/4 inch hex
head capscrews thathold the left side
panel tothe mounting tray as shown^irT
• yFigure4./. Set'this panel aside^for now.
Use an appropriately sized chain or
. portable hoist with chain ihserted
... through/the lifting eye^on top of
engine/to position the/generator set
"in^iace" over the truck frame rails
in/the desired mounting location and
. check for adequa^/clearance(over-all
/compartment dimensions, are shown in/ .
Figure 3j, / . - / '
"WARNING certain that housing base-
'plate Is adequately/supported
9. Remove thetwo 3/8-16 x 3/4 inch hex
head capscrews and ..the single (front) v..'.
3/8-16 x l-3/4^i-rich hex head capscrew', -
• that hold ^e^right side panel to .the V
mounting-"tray as shown in Figure . 4. •
carefully . lift and place this panel
;«vV,
'
on top of the generator set for now. '
NOTE: This panel will be reassembled-
after mounting':clamps and truck battery,'/'.''
cables have been installed. •. .•, :t
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7.
6

Compartment DISASSEMBLY and Installation
._CAUTION: DoNOTdisconnectorremovethe
A-bvL
AC duPlex«ceptacle
internal wiring or
r ^ theexternalcoverand gasket installedm
^£^toc>oe.j^ji*p^^^ topcenterof right sidehousingpanel.
^-k^Z,d^jflMsg^A.p*Yop*iM~NOTE: Removalofrear(back)panel-isNOT
- J ) • i / jT, • ,1cv/11> requiredforinstallationofthegenerator
S^ed hon-f (^set taet^lvf<x^r)x 560/bp^