Onan 50.0DDB-15R Series Instruction Manual

DQODQ
•it
OPERATORS
D PARTS C
UAL
LOG
FOR
ELECTRIC GENERATING SETS
DDB
SERIES
944-0302
4A74
Printed in U.S.A.

TABLE OF CONTENTS
TITLEPAGE
Introduction 1
Specifications... 2
SafetyPrecautions4
Description 7
Installation11
Operation18
General Maintenance• 23
Parts Catalog—25
WARNING
MANUFACTURER RECOMMENDS THAT ALL SERVICE IN-
CLUDING INSTALLATION OF REPLACEMENT PARTS BE
DONE BY QUA LI FIED ELECTRICA L A ND/OR MECH A N/CA L
SERVICEMEN. FROM THE STANDPOINT OF POSSIBLE IN-
JURY AND/OR EQUIPMENT DAMAGE IT IS IMPERATIVE
THATTHE SERVICEMAN IS QUALIFIED.

INTRODUCTION
FOREWORD
ThismanualisapplicabletotheDDBSerieselectric
generatingset,consistingofanOnanUR50.0KWAC
generator,drivenbya JohnDeere6329Ddiesel
engine.Informationisprovidedoninstallation,
operation, troubleshootingandpartsorderingforthe
set.Themanualshouldbeusedinconjunctionwith
theJohnDeereenginemanual,asyourspecific
enginemayhavevariationsduetooptionalequip-
mentavailable.
WARNING| Onan uses thissymbol
'throughoutthe text towarnof
possible injuryordeath.
This symbolis used towarnof
possible equipmentdamage.
MODEL IDENTIFICATION
IdentifyyourmodelbyreferringtotheMODELand
SPECIFICATIONNO.asshownontheOnan
nameplate.Electricalcharacteristicsareshownon
thelowerportionofthenameplate.
50.0DDB15R/IB
12 3 4 5
1. IndicatesKilowattrating.
2. FactorycodeforSERIESJdentification..
3.Indicatesvoltagecode.
15indicatesreconnectible
Rindicatesremoteelectricstart
4. Factorycodefordesignatingoptionalequipment.
5.Specificationletter.(Advanceswhenfactory
makesproductionmodifications.)
Ifitisnecessarytocontacta dealerorthefactory
regardingtheset,alwaysmentionthecomplete
Model, SpecNo.andSerialNo.asgivenontheOnan
nameplate.Thisnameplateinformationisnecessary
toproperlyidentifyyourunitamongthemanytypes
manufactured.Refertotheenginenameplatewhen
requestinginformationfromitsmanufacturer.The
Onannameplateislocatedontherightsideofthe
generator;theJohnDeerenameplateisontheleft
side, ontheengineblock.
Leftsideandrightsideareconsideredwhenviewedfromthe
ngineorfrontendofthegeneratingset.
IMPORTANT! RETURN WARRANTY CARD ATTACHED TO UNIT.

ENGINE DETAILS
EngineManufacturerJohnDeere
EngineSeries300—6329D
NumberofCylinders6
Displacement329cu.inches
BHP@ 1800RPM85
CompressionRatio16.3:1
Bore4.02-inches
Stroke'.4.33-inches
FuelASTMNo.2Diesel
BatteryVoltage12
BatteryGroup(Two6-Volt,135-A.H.)2H
StartingMethodSolenoidShift
GovernorRegulation5%Noload— Fullload
GENERATOR DETAILS
TypeUR15R60Hz
UR515R50Hz
UR3R60Hz
Rating(Watts)
60HertzContinuousStandby50,000(62.5KVA)
50HertzContinuousStandby40,000(50.0KVA).
ACVoltageRegulation2%
.60HertzRPM1800
50HertzRPM1500
OutputRating0.8PF.
ACFrequencyRegulation3..Hz
BatteryChargingCurrent35Amperes
CAPACITIES AND REQUIREMENTS
CoolingSystem(IncludesRadiator)5 aal.
EngineOilCapacity(Crankcase)12ats.
ExhaustConnection(inchespipethread)ats.
AIR REQUIREMENTS (1800RPM)
.EngineCombustion200CFM
RadiatorCooledEngine4185CFM
TotalforRadiatorCooledModel4385 CFM
AlternatorCoolingAir
(1800RPM)1000CFM
(1500RPM)834CFM
FuelConsumptionatRatedLoad3.9GPH
GENERAL
Height: 52.6-inches
Width! 33.0-inches
Length79.75-inches
Weight(approx.)2180-pounds

TABLE 1.UR GENERATORVOLTAGE OPTIONS
VOLTS
FREQr
PHASE "AMPERES DOUBLE
DELTA
SERIES
DELTA
PARALLEL
WYE
SERIES
WYE
REF. VOLTAGE
WIRE (W12)TAP
120/240 60Hz 1 260
X
H5
115/230
50Hz 1 216
X
H6
120/240 60Hz
3
151
X
H5
115/230
50Hz
3
125
X
H6
120/208 60Hz
3
174
X
H3
127/220 60Hz
3
164 'X H4
139/240
60Hz
3
151
X
H5.
110/190 50Hz
3
151
X
H3
115/200 50Hz
3
142
X
H4
240/416
60Hz
3
87
X
H3;
254/440
60Hz 3
82
X H4
277/480 60Hz
3 75
X
H5
220/380
50Hz 3
76
X H3
230/400 50Hz .3 72
X
H4
9X R
347/600
60Hz
3
60 H3— Not
Reconnectible
50.0KW
40,000KW
.62.5KVA
50.0KVA
60Hz
50Hz

SAFETY PRECAUTIONS
Throughoutthismanual you willfindeye-catching
flagscontainingWarningsandCautions,alertingyou
toconditionsthatcouldresult in danger to you or the
equipment, if the notice is ignored.
ONANrecommendsthat you readyourmanual and
becomethoroughlyacquaintedwith itand your
equipmentbefore you startyourunit. Theac-
cumulatedexperience of ONANengineers is
available to you,enabling you to operateyour set in
themostefficientandsafestmannerpossible.These
recommendations andthe followingsafety
precautions are for yourprotection.Studyandknow
them!
If itis necessary to makeadjustmentswhile the
unit is running, use extremecautionwhenclose
to hot exhausts,movingparts, etc.
Do not stand ona wet floorwhileworking on
electricalequipment. Use rubberinsulativemats
placed ondry woodplatforms.
REMEMBER.Mostaccidentsarecaused by failure to
followsimple and fundamentalsafetyrules or
precautions.
Most accidents can be prevented!
KNOW YOUR MANUAL - KNOW YOUR EQUIP-
MENT
Fuel System
• DO NOT fillfueltankswhileengine is running,
unlesstanks are outsideenginecompartment.
DO NOT SMOKE OR USE AN OPENFLAME in
thevicinity ofthe generator setor fueltank.
Internalcombustionenginefuelsarehighlyflam-
mable.
REMEMBER — IF YOU CAN SMELLFUMES —
YOU'RECOURTING A POSSIBLEEXPLOSION
ANDFIRE!
General
•Keepyourgenerating setandthe surrounding
areacleanandfreefromobstructions.Remove all
oildeposits;keep the floorclean and dry.
•Provideappropriatefireextinguishersandinstall
them in convenientlocations.Consultyourlocal
firedepartment forthe correcttype ofex-
tinguisher to use. Donot use foam or carbon
tetrachloride on electricalfires.Useextinguisher
rated ABC by NFPA.
•Makesurethat all fasteners on thegenerating set
aresecure.Tightensupports and clamps,keep
guards in positionoverfans,drivingbelts, etc.
• Donot wearlooseclothing inthe vicinity of
movingparts, or jewelrywhileworking on elec-
tricalequipment.
Makesurethatoilyragsare not lefton or nearthe
engine.
Fuellinesmust beof steelpiping,adequately
secured, andfreefromleaks.Pipingattheengine
should be approvedflexibleline. Donotuse
copperpipingonflexiblelinesascopperwillwork
harden and becomebrittle. Use blackpipe on
naturalgas or gaseousfuels, but notongasoline
ordiesel fuel.
Yourengineinstallationshouldbeequippedwith
ameans of positivefuelshutoff in applications
whenfuel is conductedfrom a remotesource.
Fuelsunderpressure(e.g.naturalgas or liquified
petroleumgas)shouldbecontrolledbya positive
shutoffvalve,preferablyautomatic, in addition to
anyvalveintegralwith the carburetor or gas
regulatorequipment.

Exhaust System
•Exhaustproductsofanyinternalcombustion
enginearetoxicandcancauseinjury,ordeathif
inhaled. Allengineinstallations,especiallythose
withina confine,shouldbeequippedwithan
exhaustsystemtodischargegasestotheat-
mosphere.Donotuseexhaustgasestoheata
compartment.
•Makesurethatyourexhaustsystemisfreeof
leaks. Ensurethatexhaustmanifoldsaresecure
andhavenotwarpedbyboltsunevenlytorqued.
Coolant System
•Coolantsunderpressurehavea higherboiling
pointthanthatofwater.DONOTopena radiator
orheatexchangerpressurecaporbreaka system
whiletheengineisrunning,andinnocaseuntil
thesystemhasbeenbledoff.
•Radiatorfanbeltsareguardedforyourprotec-
tion. DONOTremovecoversorguards.
• Keep your hands away from movingparts.
Ventilation System
•Checkremoteradiatorsfrequently.Removeany
dirt,debris,birdnests,etc.
•Checkventilationlouvresfrequently.Makesure
thatfree-falllouvresandmotoroperatedlouvres
openandcloseproperlyandthatthereisno
restrictioninthefreeairflow.
Electrical System
Theelectricalinstallationexteriortoyourgenerator
shouldhavebeenperformedbyqualifiedlicensed
electricians.Alllocalandstatecodesshouldhave
beenconsultedandcomplied with. Itisessentialthat
allloadcircuitbreakersadequatelyprotectelectrical
functions,allcircuitsareproperlygroundedand
wiringiscorrectcapacity.
•Tagopenswitches.
•DON'Ttamperwithinterlocks.
•Beforestartingworkonthegeneratingset,dis-
connectbatteries.Thiswillpreventinadvertent
startingoftheset.
•Useextremecautionwhenmakingadjustments
ontheelectricalcomponentsinthecontrolpanel
whiletheengineisrunning.Highvoltagesare
presentandcouldcauseseriousinjuryordeath.
•DONOTSMOKEwhileservicingbatteries.Verify
correctpolarityofbatterycablesbeforeconnec-
ting. Leadacidbatteriesgiveoffa highlyex-
plosivehydrogengaswhichcanbeignitedby
electricalarcingorbysmoking.Whenconnecting
batteries,connectthegroundleadlast.

DUALRANGE
ACVOLTMETER
VOLTAGEADJUSTING
RHEOSTAT
EXCITER
CIRCUITBREAKER
INDICATORLAMPS-INDICATEUPPER
ORLOWERSCALEONVOLTMETER
PANELLIGHTANDSWITCH
OILPRESSUREGAUGE
WATERTEMPERATURE
GAUGE
FAULTLAMP
DCAMMETER
1/4 TURNFASTENERS.TURNBOTH TO
OPENHINGEDCONTROLPANELDOORS.
PHASESELECTORSWITCH
•—RUN- STOP-REMOTESWITCH
FIGURE 1. TYPICALCONTROLPANEL (ONE FAULT LAMP)
DUALRANGE AC AMMETER
INDICATORLAMPS
INDICATEUPPER AND LOWERSCALE
ONVOLTMETER AND AMMETER—.
DUALRANGE
ACVOLTMETER
VOLTAGE
ADJUSTING
RHEOSTAT
FREQUENCY
METER
RUNNINGTIME
METER
%TURNFASTENERS-TURNBOTH
SCREWS TO OPENHINGEDCONTROL-
PANELDOORS
PANELLIGHT AND SWITCH
EXCITERCIRCUITBREAKER
PHASESELECTORSWITCH
OILPRESSURE
GAUGE
WATERTEMPERATURE
GAUGE
DCAMMETER
«UN-STOP-REMOTESWITCH
(ALSO A. RESETSWITCH FOR
ENGINEMONITOR)
FAULTLAMPS
TESTLAMPBUTTON AND
ENGINEMONITORRESETSWITCH
USEDONLY ON CONTROLPANELS
WITHFIVEFAULTLAMPS
FIGURE 2.OPTIONAL CONTROLPANEL(FIVEFAULTLAMPS)

DESCRIPTION
GENERAL
AnONANDDBserieselectricgeneratingsetisa
completeunitconsistingof'an-enginedrivenAC
generator,withcontrolsandaccessoriesasordered.
ENGINE
TheengineontheDDBisa JohnDeere6329Das
describedinenginemanual.Basicmeasurements
andrequirementswillbefoundunderSpecifications.
However,theengineusedforyourunitmayhave
variationsduetooptionalequipmentavailable,
thereforetheJohnDeeremanualshouldbe con-
sulted.
AC GENERATOR
ThegeneratorisanONANTypeUR,12 lead, 4 pole
revolving field, reconnectiblebrushlessunit.The
alternatingcurrentisgeneratedinthestatorwinding.
Thealternatorrotor,attacheddirectlytotheengine
flywheelturnsatenginespeed.Therefore,thespeed
atwhichtherotorturns,determinesgeneratoroutput
frequency.The60hertzsetoperatesat1800rpmand
the50hertzat1500rpm.Excitationisachievedby
feedingACoutputtoa voltageregulator,whereitis
comparedwitha referencevoltageintheregulator,
rectifiedandreturnedtothefieldoftheexciter,then
totheexciterarmature,rectifiedandfedtothe
generator field. TheURgeneratorisavailablein3-
phaseandsinglephase.Excitationandregulationare
thesameforeitherunit.
CONTROL PANEL
Thefollowingisa briefdescriptionofeachofthe
standardcontrolsandinstrumentslocatedonthe
faceofthepanel.SeeFigure1.
DC PANEL
PanelLightandSwitch:Illuminatescontrolpanel.
OilPressureGauge:Indicatespressureoflubricating
oilinengine(wiredtoa sensorunitlocatedonthe
engine).
WaterTemperatureGauge:Indicatestemperatureof
circulatingcoolantinengine.(Wiredtoa sensorunit
locatedontheengine.)
BatteryChargeRateDCAmmeter:Indicatesthe
batterychargingcurrent.
Run-Stop/Reset-RemoteSwitch:Startsandstopsthe
unitlocallyorfroma remotelocation.
AC PANEL
ACVoltmeter:IndicatesACgeneratoroutputvoltage.
Dualrangeinstrument:measurementrangeinuse
shownonindicatorlight.
ACAmmeter:IndicatesACgeneratoroutputcurrent.
Dualrangeinstrument:measurementrangein.use
shownonindicatorlights.
Voltmeter-AmmeterPhaseSelectorSwitch:Selects
thephasesofthegeneratoroutputtobemeasuredby
theACvoltmeterandACammeter.
VoltageRegulator:Rheostat,providesapproximately
plusorminus5%adjustmentoftheratedoutput
voltage.
ExciterCircuitBreaker:Providesgeneratorexciter
andregulatorprotectionfromoverheatinginthe
eventofcertainfailuremodesofthegenerator,
exciterandvoltageregulator.
RunningTimeMeter:Registersthetotalnumberof
hours, to 1/10th thattheunithasrun.Useittokeepa
recordforperiodicservicing.Timeisaccumulative,
metercannotbereset.
FrequencyMeter:Indicatesthefrequencyofthe
generatoroutputinhertz.Itcanbeusedtocheck
enginespeed.(Eachhertzequals30rpm.)
OPTIONAL EQUIPMENT
DC PANEL
WarningLights:Eliminatestheone"Fault"lightand
substitutesfiveindicatorlightstogivewarningof—
a.Overcrank(failedtostart)
b.Overspeed
c.Lowoilpressure
d. Highengine^t.emperature
e.Lowenginetemperature
Operationoftheselightswillbediscussedin con-
junctionwithenginemonitorpanel.
WarningLights:Indicates"Fault"inengineoperation.
ResetSwitch:Manualresetforenginemonitorafter
shut-down.
Lamp'Test:Presstotestwarninglampbulbs(when
engineisrunningonly).

CONTROL PANEL INTERIOR
Theonlyequipmentsdiscussedinthissectionwillbe
thosewhichtheoperatormayhavereasontoadjustor
inspectforservice.
TerminalBoard(TB)21:ConnectionofwireW12to
terminalsH3,H4,H5,andH6ismadeatthispoint,to
changereferencevoltagewhenreconnecting
generatorfordifferentvoltages.RefertoFigure14.
VoltageRegulator:Solidstateunit,consistingof
VR21, CR21andL21.ControlsACoutputfrom
generatoratpredeterminedlevelregardlessof load..
Regulationplusorminus 2% fromnoloadtofull load,
0.8P.F.
c.Lowoilpressure(14psi).
d. Highenginetemperature(215°F).
Onstandardcontrolpanels,allfouralarmsarewiredintoone
commonfaultlamp;onunitswithfivefaultlamps,fourhave
shutdownalarms,thefifth(lowenginetemperature)lightsa fault
lamponly.RefertoTable2.
StandardCrankingModule:Limitsenginecranking
timeto75seconds.Ifenginefailstostartafter75
secondstheenginemonitorlightsa faultlampand
opensthecrankingcircuit.
EngineMonitor:Printedcircuitplug-inmodules
providethefollowingfunctions:
1. A 75secondcrankingperiod.
2. Approximatelya 12-1/2secondtimedelayforoil
pressurebuildup.
3.Anexternalalarmcontacttolightafaultlampand
shutdownthesetforalarmconditionssuchas:
a.Overcrank(failedtostartaftercranking75
seconds).
b.Overspeed(enginespeedreaches2100rpm).
OPTIONAL MODULES
CycleCranker:Plug-inmodulereplacesstandard
crankingcircuit.Automaticallyprovidesa 15-second
cranktimeanda 10-secondresttimeforthreeONand
twoOFFcyclesin65seconds.Ifenginefailstostart,
after75-secondstheenginemonitorlightsa fault
lampandopensthecrankingcircuit.
Pre-Alarm: Givesadvancewarningforlowoil
pressureorhighenginetemperature.Requirestwo
sensorseachforenginetemperatureandoilpressure.

TABLE 2. FAULT LAMPOPTIONS
FAULT STOP EXTERNAL
PRE-
SYSTEM
FAULT:-LAMP
ENGINE
ALARM ALARM
PENNSTATE.
SINGLELIGHT Overcrank
X X X
Overspeed
X X X
LowOilPressure
X X
HighEngineTemperature
X X
STANDARD
SINGLELIGHT Overcrank
X X X,1
Overspeed
X X X
LowOilPressure
X X X
HighEngineTemperature X X X
5LIGHT Overcrank X X X
Overspeed
X X X
LowOilPressure
X X X
HighEngineTemperature X X X
LowEngineTemperature
X
5LIGHT
PRE-ALARM Overcrank
X . X X
Overspeed
X X X
LowOilPressure
X *
X X
HighEngineTemperature
X
*
X X
LowEngineTemperature X
-Withadditionaloptionalsensors.

THIMBLE
(SEEDETAIL)
DUCT
SWEEPINGELBOW
EXHAUSTLINE
TOMUFFLER
AUTOMATIC
LOADTRANSFER
SWITCH
FIGURE 3. TYPICAL INSTALLATION
10

INSTALLATION
GENERAL
Installationsmustbeconsideredindividually.Use
theseinstructionsasa generalguide.Meet
regulationsoflocalbuildingcodes,fireordinances,
etc.,whichmayaffectinstallationdetails.SeeFigure
3.
Radiatorsetcoolingairtravelsfromtherearoftheset
tothefrontend.Locatetheroomorcompartmentair
inletwheremostconvenient,preferablytotherearof
theset.Maketheinletopeningatleastaslargeasthe
radiatorarea(preferably1-1/2timeslarger).
Installationpointstoconsiderinclude:
1. Levelmountingsurface.
2. Adequatecoolingair.
3.Adequatefreshinductionair.
4. Dischargeofcirculatedair.
5.Dischargeofexhaustgases.
6.Electricalconnections.
7.Fuelconnections.
8.Waterconnections.
9.Accessibilityforoperationandservicing.
10. Vibrationisolation.
11. Noiselevels.
Engineheatisremovedbya pusherfanwhichblows
coolingairoutthroughthefrontoftheradiator.
Locatethecoolingairoutletdirectlyinfrontofthe
radiatorandascloseaspractical.Theopeningsize
shouldbeatleastaslargeastheradiator area. Length
andshapeoftheairoutletductshouldofferminimum
restrictiontoairflow.Usea ductofcanvasorsheet
metalbetweentheradiatorandtheairoutletopening.
Theductpreventsrecirculationofheatedair.
Providea meansofrestrictingtheairflowincold
weathertokeeptheroomorcompartment
temperatureata normalpoint.
LOCATION
Providea locationthatisprotectedfromtheweather
andisdry,clean,dustfreeandwellventilated.If
practical, installinsidea heatedbuildingforprotec-
tionfromextremesinweatherconditions.
MOUNTING
Generatingsetsaremountedona rigidskidbase
whichprovidespropersupport.Installvibration
isolatorsbetweenskidbaseandfoundation.For
convenienceindrainingcrankcaseoilandgeneral
servicing, mountsetonraisedpedestals(atleast6
incheshigh).Ifmountingina trailer,orforother
mobileapplications,boltsecurelyinplace.Extra
supportforthevehicleflooringmaybenecessary.
Boltingdownisrecommendedforstationaryin-
stallations.
VENTILATION
Generatingsetscreateconsiderableheatwhichmust
beremovedbyproperventilation.Outdoorin-
stallationsrelyonnaturalaircirculationbutmobile
andindoorinstallationsneedproperlysizedand
positionedventsfortherequiredairflow.See
Specificationsfortheairrequiredtooperatewithrated
loadundernormalconditionsat1800rpm.
Ashelterhousingwithelectricallyoperatedlouvresis
availableasanoption.Transformersconnected
acrossthegeneratoroutputsupplycurrenttothe
motors.
Whenthegeneratorisoperating,currentinthe
transformersactuatethemotorsandopenthe
louvres.Thelouvresareheldopenforthedurationof
thesetoperation,thenareclosedbyreturnsprings
whenthesetisshutdown.
Citywatercooledsetsdonotusetheconventional
radiator.A constantlychangingwaterflowcoolsthe
engine.Ventilationisseldoma problem,butsufficient
airmovementandfreshairmustbeavailableto
properlycoolthegenerator,disperseheatconvected
offtheengineandsupportcombustionintheengine.
Forsmallcompartments,aductofequalorlargerarea
thangeneratoroutletisrecommendedtoremovethe
heatedairfromthegeneratorairoutlettotheoutside
atmosphere.Limitbendsanduseradiustypeelbows
whereneeded.A larger,wellventilatedcompartment
orroomdoesnotrequirea hotairduct.
Installationsmadeina smallroommayrequire
installationofanauxiliaryfan(connectedtooperate
onlywhentheplantisrunning)ofsufficientsizeto
assureproperaircirculation.
11

CITY WATER COOLING
Anoptionalmethodofenginecooling,inplaceofthe
conventionalradiatorandfan,usesa constant
pressurewatersupply.ThisisreferredtoasCITY
WATERCOOLING.Therearetwovarietiesofcity
watercooling:theHEATEXCHANGERSYSTEMand
STANDPIPESYSTEM.SeeFigures4 and5.
C EXPANSION
TANK
•HEATEXCHANGER
•TOENGINE
=FROM
ENGINE
DRAIN
SOLENOID
VALVE
(OPENSWHEN
PLANTISRUNNING)
LOCKSHIELD
VALVE
(RATEOFFLOW)
WATER
IN
STRAINER
ANTI-SIPHON—
STAND
PIPE
SOLENOIDVALVE
(OPFNSWHEN
PLANTISRUNNING)
WATER
IN
DRAIN
— FROM
ENGINE
:TO ENGINE
—LOCKSHIELDVALVE
(RATEOFFLOW)
STRAINER
FIGURE5.TYPICALSTANDPIPESYSTEM
TheSTANDPIPESYSTEMusesa mixingortemper-
ingtank.Coolingwaterthatcirculatesthroughthe
enginemixeswitha sourceofcool"raw"water.The
"raw"watersupplymustbefreeofscaleforminglime
orotherimpurities.
FIGURE4.TYPICALHEATEXCHANGERSYSTEM
TheHEATEXCHANGERprovidesforaclosedengine
coolingsystem.Enginecoolantflowsthrougha tubed
chamber,keepingthecoolantseparatefromthecool
"raw"watersupply.Thecoolantchambermustbe
filledforoperation,asfora radiatorcooledset.
Onbothsystemsuseflexiblepipe.forconnecting
watersupplyandoutletflowpipestoengine.Pipethe
outletflowtoa convenientdrain.Installanelectric
solenoidvalveanda rateofflowvalveinthewater
supplyline.Theelectricsolenoidvalveopensand
allowswaterflowthroughthesystemonlywhenthe
plantoperates.Therateofflowvalve,either
automaticormanual,providesfortheproperflowrate
totheengine.Adjusttheflowtomaintainwater
temperaturebetween165degreesand195degrees
whileviewingthewatertemperaturegauge.
Beforefillingcoolingsystemcheclcallhardwareforsecurity.This
includeshoseclamps,capscrews,fittingsandconnections.Use
flexiblecoolantlineswilhheatexchanger,standpipeorremote
mountingradiator.
WATER JACKET HEATER (Optional)
Thisheaterisinstalledtomaintainanelevatedengine
temperatureinlowerambienttemperature
applications.Itheatsandcirculatesenginecoolant,
andisthermostaticallycontrolled(Figure19).
12

EXHAUST
WARNING Inhalationofexhaustgasescanresultin
death.
Engineexhaustgasmustbepipedoutsidebuildingor
enclosure.Donotterminateexhaustpipenearinlet
ventsorcombustiblematerials.Anapprovedthimble
(Figure6)mustbeusedwhereexhaustpipespass
throughwallsorpartitions.Pitchexhaustpipes
downwardorinstalla condensationtrap(Figure7)at
thepointwherea riseintheexhaustsystembegins.
Avoidsharpbends;usesweepinglongradiuselbows.
Provideadequatesupportformufflersandexhaust
pipes. RefertoFigure3 fora typicalexhaustinstalla-
tion. Shieldorinsulateexhaustlinesifthereisdanger
ofpersonalcontact.Allowatleast9-inchesof
clearanceifthepipesrunclosetoa combustiblewall
orpartition.Usea pipeatleastaslargeasthe3-inch
pipesizeoutletdftheenginewitha flexibleportion
.IFEXHAUSTLINEMUSTBEPITCHEDUPWARD.
.CONSTRUCTA TRAPOFPIPEFITTINGSAT
POINTOFRISE
DRAINCONDENSATIONTRAP
B4,.i"WHPERIODICALLY
FIGURE7. EXHAUSTCONDENSATIONTRAP
RAINCAP
DRIPCAP
HOLESINENDOF
INNERSLEEVE
ROOF
•HOLESIN
JfENDOF
.,_-'INNERSLEEVE
WALLORPARTITION-|[WHII|II|IB
NOTEVENTILATEDTHIMBLEDIAMETER6"LARGER
B4, THANEXHAUSTLINE
FIGURE6.EXHAUSTTHIMBLE
betweentheengineandthemuffler.Donotconnecta
flexiblelinetotheexhaustmanifold.Minimum
diametersandmaximumlengthsofpipeareas
follows:
SingleExhaustsystem:
2'/2-inchpipe58-feet
3-inchpipe191-feet
3'/2-inchpipe419-feet
Maximumpermissibleexhaustrestriction(back
pressure)is25-inchesH2O.(1.84-inchesHg.).
13

FUELPUMP
RETURN LINI.
INJtCTOR
FUELRETURN
Allmodelsrequirefuelreturn
linefrominjectors to tank.
VENTLINE •
FLOATTYPE
VALVE
'DAY'TANK
5GALMIN.
CAPACITY
ISIZELARGER
OVERFLOW
FUELTRANSFER
PUMP: - ELECTRIC
MOTORDRIVEN
SUPPLYLINE
NOTE: Whereused.Float-type
"Day"TankandLines
must be belowinjector
returnoutlet!
WARNING: Itis necessarythat an overflow
pipe be installedbetween theday tank and
mainfueltank. A hazardousfirecondition
existswithspilled fuel.
- FILL
PIPE
UNDERGROUND
FUEL TANK
u
FIGURE 8. DAYTANKINSTALLATION
14

FUEL SYSTEM
TheJohnDeereenginesusedontheDDBsetsare
designedforusewithASTMNo.2Diesel fuel. They
willhowever,operateondieselfuelswithinthe
specificationsdelineatedintheJohnDeereengine
manual.
FUEL CONNECTIONS
Checklocalregulationsgoverningtheinstallationof
afuelsupplytank.
Inanydieselengineinstallation, fuel, systemcleanlinessisof
utmostimportance.Makeeveryefforttoprevententranceof
moistureorcontaminantsofany kind. Donotuselinesorfittingsof
galvanizedmaterial.
Afuelliftinexcessof10-feetisnotrecommended
withouta daytankinstallation,becauseoffuel
drainage.Horizontalrun,ifthesupplytankislevel
withthefuelpumpshouldnotexceed25-feet.
However,a daytankisagainrecommended.
Thefuelinletistothetransferpumpandisthreaded
for 1/8-ipch pipe.Injectorpumpreturnlineiscom-
monwiththeinjectors'retumline,andrequiresa 1/8-
inchlowpressurehoseconnection.
FIGURE9.BATTERYCONNECTION
DAY TANK
Generatorsetinstallationsmaybeequippedwithan
optionalintegralfuelDaytank.A floatoperatedvalve
controlsfuelflowofupto300psiintothefueltank.
Thecorrectlevelismaintainedtoassurea constant
sourceof fuel. Itisnecessarytoinstallanoverflow
linebetweentheDaytankandthemainfueltank.
Refertotheinstallationsincludedwiththetank.See
Figure8 foranexampleofa Daytankinstallation.
BATTERY
Startingtheplantrequires12-voltbatterycurrent.
Usetwo6-volt(seespecification)batteriesfora
normalinstallation.Connectthebatteriesinseries
(negativepostoffirstbatterytopositivepostof
second)asinFigure9.Necessarybatterycablesare
onunit.Servicethebatteriesasnecessary.Infrequent
plantuse(asinemergencystandbyservice)may
allowthebatteriestoself-dischargetothepoint
wheretheycannotstarttheplant.Ifinstallingan
automatictransferswitchthathasnobuilt-incharge
circuit,connecta separatetricklecharger.Onan
automatictransferswitchesincludesucha battery
chargingcircuit.
WARNING Donotsmokewhileservicingbatteries.Lead
acidbatteriesgiveoffexplosivegaseswhile.
beingcharged.
BATTERY, HOTLOCATION
Batterieswillselfdischargeveryquicklywhenin-
stalledwheretheambienttemperatureisconsistently
above90°F,suchasina boilerroom.Tolenghten
batterylife,dilutetheelectrolytefromitsnormal1.275
specificgravityreadingatfullchargetoa 1.225
reading. Thecrankingpowerisreducedslightlywhen
theelectrolyteissodiluted,butifthetemperatureis
above90°F,thisshouldnotbenoticed.Thelengthen-
edbatterylifewillbeworththeeffort.
1. Fullychargethebattery.
2. Withthebatterystilloncharge,drawoffthe
electrolyteabovetheplatesineach cell. DONOT
ATTEMPTTOPOUROFF;useanhydrometeror
fillerbulbanddisposeofitinasafemanner.Avoid
skinorclothingcontactwiththeelectrolyte.
3.Refilleachcellwithdistilledwater,tonormal
level.
4. Continuechargingforihourata4to6hourrate.
5.Testeach cell. Ifthespecificgravityisstillabove
1.255, repeatsteps2,3,and4 untilthereadingis
reducedto 1.225. Usually,repeatingstepstwiceis
sufficient.
15

REMOTECONTROLCONNECTIONS
Provision is madeforaddition of remotestarting.This
isaccomplished ona4 placeterminalblocksituated
within the control box. Connect one or moreremote
switchesacrossremoteterminal andB+ terminal as
shown in Figure 10.If the distancebetween the set
andremotestation is lessthan1000-feet, useNo. 18
AWGwire;between 1000- and 2000-feet, useNo.
16AWGwire.
COMMON
ALARM
I I
ALM GRDRMT
REMOTE
SWITCH
B+
o o
FIGURE 10. REMOTESTARTING
WIRINGCONNECTIONS
Mostlocalregulationsrequirethatwiringconnec-
tions be made bya licensedelectrician and that the
installation be inspected and approvedbeforeopera-
tion. All connections,wiresizes,etc.mustconform to
requirements of electricalcodes in effect atthe
installationsite.
If the installation isfor standbyservice, a double
throwtransferswitchmustalways be used.Connect
thisswitch(eitherautomatic or manual) so that itis
impossible for commercialpower and generator
current to be connected-to the load at thesametime.
Instructions for connecting an. automaticload
transfercontrol are includedwithsuchequipment.
GEN.
LINE LOAD
NOTE: SHOWNWITHLINECONNECTED TO LOAD.
FIGURE 11. LOADTRANSFERSWITCH
Control Box Connections:Thefactoryshipsthese 12
leadgeneratorswithloadconnectionwires NOT
connectedtogether in thecontrolbox.These12wires
arelabeled Tl through T12and must be brought
togetherbeforemakingloadconnections.Proceed as
follows:
1. Removeeitherright,left ortop panelfromcontrol
box. See Figure 12.
2. Connectwirestogetherasshown on paneland in
Figure 13 according to voltagedesired.
3.Openhingedcontrolpaneldoors.Connectlead
fromterminal 63to correctterminal for voltage
desired. Theseterminals are labeled H2,H3,H4,
H5 andH6.See Figure 14.
FIGURE 12. CONTROL BOX (SIDEPANELREMOVED)
4. Closefrontpanel and securewith 1/4 turn
fasteners.
5.Connectloadwires to generatorleads.
Precedinginstructions donot apply to modelswith a 347/600
voltage(designated9X) or a 120/240voltage(designated3R);Ihese
connections are made atthe factory. The installermustonly
connectloadwires.
MNIIATM
COMNICIIOM
tCNIMATIC
•1AOIAM
OIMIIATMCOMNICTIOMWltlMG•lAOBAM
(WITHCUIIINfTIANftMMMiaS WMM UMBI
IM/MO
m/uo
iar/*io
US/IO0
i»«A«o
in/400
ntfuo
IMAOO
ii n ?»tn nm T4 l« TITT 1>IIO
TI noi* 17 tain 14 toiainiiio
IWtil 111 11TT 14 11 11 11
120/240VOLT, I PHASE,
60CYCLE 347/600VOLT.
3 PHASE,
60CYCLE
NAMEPLATEVOLTAGE
CODE 3
Tl
TO
T2
CONNECT LEAD FROM
TERMINAL 63 TOH5
NAMEPLATEVOLTAGE
CODE 9X
Tl*
,T2
•TO
T3
CONNECTLEADFROM
TERMINAL 63TOH5
FIGURE 13. VOLTAGECONNECTIONS
16

CONNECTFROM
TERMINAL#63
TOEITHERH3.H4
H5. ORH6.
Anycombinationof 1 phaseand3 phaseloadingcan
beusedatthesametimeaslongasnoterminal
currentexceedstheNAMEPLATEratingofthe
generator.Ifno3 phaseoutputisused,usable 1 phase
outputis2/3of3 phaseKVA.
_1_
r~~r~
240V
120V 240V L2-
1
120 V
240V
i
^^2(^0V -
>1
•°CL
rsm
i3 y
•DONOTUSETHIS
CONNECTIONFORANY
120VOLTLOADS.
FIGURE16.3 PHASE,DELTACONNECTION,12LEAD
FIGURE14.CONNECTINGLEADFROMTERMINAL63
120/240Volt,SinglePhase,12Lead:Terminal con-
nectionL0canbetheground(neutral).For120volts,
connectthehotloadwirestoeithertheLlorL2
connection,Figure15.Connecttheneutralloadwire
totheL0connection.Two120voltcircuitsarethus
available,withnotmorethan1/3theratedcapacityof
thesetavailableoneithercircuit.Ifusingboth
circuits,besuretobalancetheloadbetweenthem.
For240volts,connectoneloadwiretotheL1
connectionandthesecondloadwiretotheL2
connection.TerminalconnectionL0isnotusedfor
240voltservice.
"1J
120V
I20V
__L_
240V
FIGURE15.120/240VOLT,SINGLEPHASE,12LEAD
3Phase,4 Wire,WyeConnectedSet;12Lead:The3
phase,4 wiresetproduceslinetoneutralvoltageand
linetolinevoltage.Thelinetoneutralvoltageisthe
lowervoltageasnotedontheunitnameplate,andthe
linetolinevoltage.isthehighernameplatevoltage.
For3 phaseloads,connectseparateloadwiresto
eachofthesetterminalsLl , L2andL3.Singlephase
outputisobtainedbetweenanytwo3 phaseter-
minals.
TheterminalmarkedLOcanbegrounded.For 1 phase
loads, connecttheneutral(white)loadwiretotheL0
terminal. Connecttheblackloadwiretoanyoneof
theotherthreeterminals— Ll,L2or'L3.Three
separate1 phasecircuitsareavailable,withnotmore
than1/6theratedcapacityofthesetfromanyone
circuit.
Ifusing 1 phaseand3 phasecurrentatthesametime,
usecaretoproperlybalancethe 1 phase load, andnot
toexceedratedlinecurrent.
Figure17showsloadconnectionsfor120/208voltage.Other
voltagesareavailablefromeitherparallelwyeorserieswye
illustrationinFigure13.
120/240Volt,3 Phase,4 WireDeltaConnectedSet;12
Lead: The3 phaseDeltaconnectedsetisdesignedto
supply120-and240volt, 1 phasecurrentand240volt,
3phasecurrent,Figure16.For3 phaseoperation,
connectthethreeloadwirestogeneratorterminals
Ll, L2andL3—onewiretoeachterminal.For3phase
operationtheL0terminalisnotused.
For120/240volt,1 phase,3 wireoperation,terminals
LlandL2arethe"hot"terminals.TheL0terminalis
theneutral,whichcanbegroundedifrequired.For
120voltservice,connecttheblackloadwiretoeither
theLlorL2terminal.Connecttheneutral(white)wire
totheL0terminal.Two120voltcircuitsareavailable.
®' 208V
\^1
\120V
\ L0 til
I2QV f
208V
vI
~—L|-\
208V L2
-.13^
>«
_-L_
FIGURE17.3 PHASE,WYECONNECTION,12LEAD
17

OPERATION
GENERAL
ONANDDBSerieselectricgeneratingsetsaregivena
completerunningtestundervariousloadconditions
andarethoroughlycheckedbeforeleavingthefac-
tory.Inspectyourunitcloselyforlooseormissing
partsanddamagewhichmayhaveoccurredintransit.
Tightenlooseparts,replacemissingpartsandrepair
anydamagebeforeputtingsetintooperation.
PRESTART SERVICING
LubricationSystem:Engineoilwasdrainedpriorto
shipment.Fillenginetocapacitiesshown.After
enginehasbeenrun,checkdipstick,addoiltobring
leveltofullmark.Recordtotalcapacityforfutureoil
changes.Donotmixbrandsorgradesoflubricating
oils.
AMBIENTTEMPERATURE SINGLEVISCOSITY MULTI-VISCOSITY
Below-10oF(-230C) SAE5W SAE5W20
Between-10°F and32°F SAE10W SAE10W30
(-230C and0oC)
Above32°F (0°C) SAE30 NotRecommended
Useoilconforming APICD/SD APICC/SE,CC/SD
tothesespecifications MIL-L-2104C* orSD
Series3* MIL-L-46152
*APICCorCD
Oilcapacities(nominal)
OilPanandFilter— 12quarts
CoolingSystem:Coolingsystemwasdrainedpriorto
shipment.Fillcoolingsystembeforestarting.
Nominalcapacityis5 gallons.Forunitsusingeithera
radiatororheatexchanger(citywatercooled),fillthe
systemwithcleansoftwater.Usea goodrustand
scaleinhibitoradditive.Ifa possibilityexistsofa
radiatorcooledsetbeingexposedtofreezing
temperaturesuseanti-freezewithanethylene-glycol
base. Duringinitialenginerun,checkthecoolant
levelseveraltimesandreplenishifnecessaryto
compensateforairpocketswhichmayhaveformed
duringfilling.RefertoJohnDeereenginemanualfor
additionalinformation.
r^^J^j^^l 1.Verifythattheelectricsolenoidvalveused
L^^^^^^X withcitywatercooledplantsisopenbefore
initialstartingofplanttoallowcoolantchambersto fill.
Overheatinganddamagetotheenginecouldresultfrom non-
compliance.
2. Ifengineisequippedwitha coolingsystemfilter,donotuse
antifreezewithananti-leakformula.Thestopleak elementcan
preventorretardthecoolantflowthroughthefilter,thereby
eliminatingthefilteringprocesscompletely.
3.Becarefulwhencheckingcoolantunderpressure.Itisadvisable
toshutenginedownandbleedoffpressurebeforeremoving
pressurecap.Severeburnscouldresultfromcontactwithhot
coolant.
FuelSystem:RefertotheJohnDeereenginemanual
forfueloilspecifications.Checkwithfuelsupplier
andensurethatfuelsuppliedmeetsthe
specifications.Filterorstrainfuelwhenfillingtank.
Fuelsupplytanksshouldbekeptasnearlyfullas
possiblebytoppingupeachtimeengineisused.
Warmfuelreturningfromtheinjectorpumpheatsthe
fuelinthesupplytank.Ifthefuellevelislowincold
weather,theupperportionofthetanknotheatedby
returningfueltendstoincreasecondensation.In
warmweatherboththesupplytankandfuelarewarm.
Coolnightairlowersthetemperatureofthetankmore
rapidlythanthetemperatureofthe fuel. Againthis
tendstoincreasecondensation.
Condensatemixingwiththesulphurinthefuelforms
asulphurousacidwhichwillcorrodeanddamagethe
engine.KEEPFUELCLEAN.
WARNING DONOTSMOKEwhilehandling
fuel. Diesel
fuelisflammable.
PrimingFuelSystem:Verifythatallconnectionsin
thefuelsystemaresecureandnoleaksexist.Proceed
withprimingasfollows:
1. Loosenbleedplugontopoffuelfilter.Pump
primerlever(Figure18)untila solidstreamof
fuel, freeofairbubbles,flowsfrombleedplug.
2. Securebleedplug.
3.Looseninletfuellineoninjectorpump.Operate
primerleveronfueltransferpumpuntila solid
streamof fuel, freeofairbubbles,flowsfrominlet
lineopening.
4. Secureinjectorpumpfuelinletline.
5.Leavefueltransferpumpprimingleveratlowest
pointofstroke.
18