Onan RDJF Series User manual

OPERATORS MANUAL
AND
PARTSCATALOG
FOR
ELECTRIC GENERATING SETS
RDJF
SERIES
0^
974-0308 1A-AA7A
Printed InU.S.A.

INTRODUCTION
THISOPERATOR'SMANUALCONTAINSINFORMATION
PERTAININGTOTHEINSTALLATION,OPERATION,AND
MAINTENANCEOFYOURONANUNIT.A PARTSCATALOG
ISALSOINCLUDEDINTHISMANUAL.
WESUGGESTTHATTHISMANUALANDTHEWIRING
DIAGRAMWHICHACCOMPANIESEVERYONANUNITBE
RETAINEDANDREFERREDTOWHENMAKINGEQUIP-
MENTADJUSTMENTSORORDERINGPARTS.ADDITIONAL
COPIES.AREAVAILABLEFORA NOMINALCHARGEFROM
YOURONANDISTRIBUTOR.
WHENORDERINGPARTSREMEMBERTOINCLUDETHE
ONANMODEL,SPECIFICATIONLETTER,ANDSERIAL
NUMBERLOCATEDONTHENAMEPLATEOFYOURONAN
UNIT.THISISESSENTIALTOENSURETHECORRECTPART
ISSHIPPEDTOYOU.
FOR MAJORREPAIRSERVICE,CONTACTYOURONAN
AUTHORIZEDDISTRIBUTOR.
WARNING
ONAN RECOMMENDS THAT ALL SERVICE INCLUDING
INSTALLATION OF REPLACEMENT PARTS BE DONE BY
QUALIFIED ELECTRICAL AND IOR MECHANICAL SER-
VICEMEN. FROM THE STANDPOINT OF POSSIBLE INJURY
AND/OR EQUIPMENT DAMAGE IT IS IMPERA TIVE THA T
THE SERVICEMAN IS QUALIFIED.

GENERAL INFORMATION
MODELIDENTIFICATION
Instructionsinthismanualmayrefertoa'specific
modelofgeneratingset;identifythemodelby
referringtotheMODELandSPEC(specification)NO.
asshownonthesetnameplate.Electrical
characteristicsareshownonthelowerportionofthe
setnameplate.
HowtointerpretMODELandSPECNO.
17.0RDJF- 3CR/ 96D
TABLEOFCONTENTS
TITLEPAGE
GeneralInformation1
Specifications2
DimensionsandClearances3
Description5
Installation9
Operation17
Adjustments21
ServiceandMaintenance23
TroubleshootingGuide25
PartsCatalog..-.27
34
1. Factorycodeforgeneralidentification.
2. SpecificType:
C- Indicatesreconnectible.
R- REMOTEtype.Electricstarting.Forperma-
nentinstallation,canbeconnectedtooptional
accessoryequipmentforremoteorautomatic
controlofstartingandstopping.
3.Factorycodeforoptionalequipment.
4. Specification(Spec)letter(advanceswhenfac-
torymakesproductionmodifications).
WARN/NG~\This/symbolisu/edtowarnoffanypossible
Jpersonalinjury,j
OnanUsesthissymbolthroughoutthe|extto
warnpfpossibleequipmentdamage.
Qnan
MANUFACTURER'S GENERAL
WARRANTY
ManufaciurerextendilotheoriginalpurchaserofGoodsforuse,Ihefollowing
warranties,subject(oIhequalificaiionsindicated:
(»)Manufacturerwarrantssalisfacloxyperformancefora periodofone(1)yearfromthe
dateeachproduciisplacedinservice,solongnssuchproductisinstalled,operatedand
servicedinaccordancewithManufacturer'swrilteninsimeiions.THISWARRANTY
ISINLIEUOFALLOTHERWARRANTIES.EXPRESSEDORIMPLIED.
INCLUDINGFITNESSFORA PARTICULARPURPOSE.
(b) Manufacturer'sliabilityandpurchasers"soleremedy fora failureofGoodstoperform
aswarranted,andforanyandallolherclaimsarisingouioflhepurchaseanduseofihe
Goods,includingnegligenceonthepanofManufacturer.shallbelimitedlotherepair
orreplacement ofGoodsreiurned loManufacturer'sfacioryoroneofitsAuthorized
ServiceSiaiions,tronsponationprepaid.Thecostofanylaborincludedshallbeas
,specifiedinManufacturer'swritteninstructions.MANUFACTURERSHALLIN
NOEVENTBELIABLEFORINCIDENTALORCONSEQUENTIAL
DAMAGES.'
(OAIIclaimsshallbebroughitoManufacturer'sattentionwithinThiny(30)daysafter
discoverythaiiheGoodsfailedtoperformoswarranted,butinnoeventshalla claim
beacceptedafterone(1)yearfromihedatesuchproduciisplacedinservice.
Nopersonisauthorizediogiveanyotherwarrantyortoassumeanyoiherliabilityon
Manufacturer'sbehalfunlessmadeorassumedinwritingbyanOfficerof
Manufacturer,andnopersonisauihorizcdtogiveanywarraniyorassumeany
liabiliiiesoniheManufacturer'sbehalfunlessmadeorassumedinwritingbysuch
Manufacturer.
IMPORTANT...RETURN WARRANTY CARD ATTACHED TO UNIT

SPECIFICATIONS
GENERAL
Nominaldimensionsofset(inches)
Unhoused ("40-1/8 h x 27w x 62Ig
Housed"40-1/8h x 27w x 73:13/16Ig
Weight(Nominal)
Unhoused.'.1120Ib.
Housedr 1220Ib.
ENGINE DETAILS
Numbercylinders(verticalin-line)4
Displacement(cubicinch)\ 140
Cylinderbore)3-1/2inch.
Pistonstrokef 3-5/8.inch
Compressionratio: ^19to1 7
RPM(for60Hertz)v1800
RPM(for50Hertz)1500
Exhaustconnection(pipetapped)\^-1/2inch^
GovernorInternalFlyballType
(ExtemallyAdjustable)
AircleanertypeDry
Diesel fuel lift (maximum feet) , 6\,
Oilfilter" "FullFlowType-
CAPACITIES AND REQUIREMENTS
Batteryvoltage12Volt
Batterysize(ACplant)
SAEgroupIH2 inSeries
Amp/hr,SAE20-hr(nominal)'.105
Startingbysolenoidshiftstarterwithover-runningclutchyes
Centrifugalstart-disconnectswitchyes
Batterychargerateamperes(normal)2
Chargeammeterscale/ 5-0-5
*OilcapacityinU.S.quarts(refill)-"6" ' ^
Watercapacity(radiatorcooled)12quarts
Ventilationrequired(cfmat1800rpm)
Engine2750
Generator125
Combustion62
GENERATOR DETAILS *" J
Outputisratedatunitypowerfactorloadonthesemodels1 Phase
Outputisratedat0.8powerfactoronthesemodels3 Phase
Rating(ACoutputinwatts)
60Hertz- ContinuousStandby17,500
50Hertz- ContinuousStandby14,500
ACvoltageregulationPlusorMinus3%
ACfrequencyregulation5%
GeneratortypeRevolvingField
120/240VoltsinglephasemodelreconnectibleYes
Broadrange3-phase12-leadreconnectible(BeginSpecAA)Yes
Excitation(PriortoSpecAA)'...•StaticExciter
Excitation(BeginSpecAA)BrushlessExciter
*- Plus.1/2quartfornewfilter.

DIMENSIONS AND CLEARANCES
Allclearancesgiven at roomtemperature of 70° F.
Alldimensions in inchesunlessotherwisespecified.
CYLINDER
CylinderDiar
leterLimits.
CAMSHAFT
BearingJournalDiameter,Front.
BearingJournalDiameter,Rear
BearingClearance Lir:i
EndPlay,Camshaft.
CamTappetDiameter
CamTappetHoleQiameter
CONNECTING RODS
LargeBoreDiameter.
Small Bore Diarneter
g..
DistanceCenter/LargeBearingBore to Small B/re
Clearance,BeaFing-to-Crankshaft
CRANKSHAFT
MainBearingJournalDiameter.
MainBearii|gClearance
Connecting'RodJournalDiameter. .
RodBearirfgClearance
EndPlay,Crankshaft
PISTON I
PistonClearance to CylinderWall(Meafure 90c
OilRingGroove) ,
toPin,JustBelow
Minimum
2.500
1.1875
.0015
.007
.8725
.8755
2.1871
1.044
5.998
.001
3.4995
2.2437
.0030
2.0600
.0019
.010
.0055
Maximum
2.505
1.1880
.0030
.039
.8730
.8765
2.1876
1.045
6.002
.003
3.5005
2.4445
.0043
2.0605
.0038
.015
.0075
PISTON PlN
PistonClearance
Connecting Rod Bushing ThumbPush
Fit
.0002.0007
PISTONRINGS
PistonRing Gap
RingWidthl, Top
I 2nd
ISrd.
VALVE, INTAKE(StelliteFaced)
StemDiameter |.
Guide.Clearance |.
ValveFace .|...
ValveCleararfce
VALVE, EXHAUST(StelliteFaced)
StemDiameterl•.../.
GuideClearance
ValveFace ...
ValveClearance
.010
.0925
.0925
.0925
.3405
.0025>
.020
.0935
.0935
.0935
.0415
.0030
.3415
.0045

VALVE GUIDE
Length
OutsideDiameter
InsideDiameter(AftgiTReamin
Exhaust
Intake
CylinderBlockgbreDiameter |
VALVE SEATS /Stellite)
ValveSeatBpre
Diameter
Depth(promCylinderHeadFace)
SeatInseitOutsideDiameterj.
SeatWidith *
SeatAnjjle
AvailableOversizes
1-25/32
4690 .4695
.345
.343
.468
1.362
.439
1.365
1/16
45c
.002, .005,.010,.025
VALVESPRINGS
Load' ValveOpen
Load, ValveClosed 87.2
lbs.
45 lbs.
97.2 lbs.
49 lbs.

DESCRIPTION
GENERAL
AnOnanRDJFSerieselectricgeneratingsetconsists
ofa four-cylinder,in-linedieselengineanda 17.5KW
(14.5KWfor50Hertz)alternatingcurrentgenerator
withstandardoroptionalequipmentasordered.
ENGINE
TheRDJFenginehas140cubicinchpistondisplace-
ment,19to1 compressionratio,andisradiator-
cooled. Basicmeasurementsandotherdetailsare
listedunderSpecifications..
AC GENERATOR
TheYDgeneratorsbeginningwithSpecAA(Figure1)
arefour-pole,revolving field, brushlessexciter
modelsofdrip-proofconstruction.Generatordesign
includesbothsingleandthree-phase,60and50hertz
typegenerators.Thegeneratorrotorconnectsdirect-
lytotheenginecrankshaftwitha taperedshaftand
key.Thegeneratorisfastenedtotheenginebythe
rotor-through-studwhichpassesthroughtherotor
shaft;ithasa nutontheoutsideoftheend bell. A
centrifugalblower,onthefrontendoftherotorshaft,
circulatesthegeneratorcoolingairwhichisdrawnin
throughtheendbellcover,overtherotor,and
dischargedthroughanoutletattheblowerend.
Aballbearingintheendbellsupportstheouterendof
therotorshaft.Theendbellandgeneratorstator
housingareattachedbyfour-through-studswhich
passthroughthestatorassemblytotheengine-
generatoradapter.Thebrushlessexciterstator
mountsintheendbellwhiletheexciterrotorandits
rotatingrectifierassembliesmountonthegenerator
rotorshaft.
Thebasicoperationofthegeneratorandvoltage
regulator,involvesthestator,voltageregulator,ex-
citerfieldandarmature,a fullwavebridgerectifier,
andthegeneratorrotor.Residualmagnetisminthe
generatorrotoranda permanentmagnetembedded
inoneexciterfieldpolebeginthevoltagebuild-up
processasthegeneratorsetstartsrunning.Single-
phaseACvoltage,takenfromoneofthestator.
OVERALLLENGTH
KEY
BRUSHLESS.
^EXCITERROTOR
TORQUETO
130TO150'
FT. LBS.
TORQUETO
55-60FT.LBS.
ROTOR-
THROUGH-STUO
ROTATING
RECTIFIER
ASSEMBLIES
\COVER
(HOUSED)
COVER
BAFFLE
STATOR-
THROUGH-STUD
STATOR ROTOR
BRUSHLESS
EXCITERSTATOR
-TORQUETO35-38FT.LBS.
ENDBELL
FIGURE1.GENERATOR(CUTAWAYVIEW)

windings,isfedtothevoltageregulatorasa reference
voltageformaintainingthegeneratoroutputvoltage.
TheACreferencevoltageisconvertedtoDCbya
siliconcontrolledrectifierbridgeonthevoltage
regulatorprintedcircuitboardandfedintotheexciter
fieldwindings.Theexciterarmatureproducesthree-
phaseACvoltagethatisconvertedtoDCbythe
rotatingrectifierassembly.TheresultantDCvoltage
excitesthegeneratorrotorwindingtoproducethe
statoroutputvoltagefortheAC load.
VOLTAGEREGULATOR
LOCATION
WIO
0
VR2I
®
T2I CMR2I
REFERENCE
VOLTAGE
TRANSFORMER COMMUTATING
REACTOR
TB2I9
NOTE: FIELD
BREAKERIS
MOUNTEDON
PANEL
FIGURE2..VOLTAGEREGULATOR
ThegeneratorrotoralsoproducesACvoltage(19to
21volts)inthechargingwindingofthestatorwhichis
convertedtodirectcurrentforbatterycharging.
VOLTAGE REGULATOR (Spec AA)
Theline-voltageregulatorontheJ-seriesgenerator
setsisanallsolidstatedevice;thatis,norelaysor
tubesareneeded.Basiccomponentsofthevoltage
regulatorare:
•PrintedcircuitboardVR21
•VoltagereferencetransformerT21
•CommutatingreactorCMR21
•FieldcircuitbreakerCBg^
•Voltageadjustrheostat(iEip(Optional)
Figure2 showstheabovecomponentsina typical
controlboxonradiatorcooledelectricgenerating
sets.
CONTROLS
Thestandardradiator-cooled,dieselpowered
generatingsetcontrolboxhasanupperanda lower
instrumentpaneldoor,Figure3.Standardcontrol
componentsincludea batterychargerateDC
ammeter,a RUN-STOP-REMOTEswitch,HEATER
switch, OILPRESSUREgauge,WATER
TEMPERATUREgauge,anda fieldcircuitbreaker.
Optionalcontrolsthatmaybeaddedontheupper
doorpanelincludethreeACammeters,anAC
voltmeter,a runningtimeHOURmeter,a phase
selectorswitch,a 50or60Hertzfrequencymeter,line
circuitbreakers,anda voltageregulatoradjustknob.
Optionalcontrolsthatmaybeaddedonthelower
paneldoorincludea PLANTFAILEDTOSTARTfault
lamp, a CRANKINGLIMITER,andthreefaultindica-
tionlampsforLOWOILPRESSURE,HIGHWATER
TEMPERATURE,andOVERSPEEDwiththeir
associatedpushbuttonresetswitches.
CONTROL PANEL COMPONENTS
ControlsandinstrumentsontheRDJFseriescontrol
panelsvaryaccordingtothecustomerspurchase
order.Thefollowingisa briefdescriptionoftypical
componentslocatedonthepanels.
Standard:
Run-Stop-RemoteSwitch:Startsandstopstheunit
locallyorfroma remotelocation.
PreheatSwitch:Controlsmanifoldheaterandglow
plugs.
BatteryChargeRateDCAmmeter:Indicatesthe
batterychargingcurrent.

AC
AMMETERS
WATE
HEATERSWITCH
RUN-STOPSWITCH
DCAMMETER
TEMPERATUREGAUGE
AC
VOLTMETER
PHASE
SELECTOR
SWITCH
FREQUENCY
METER
VOLTAGE
ADJUST
RHEOSTAT
INDICATORS
RESET
BUTTONS
FIGURE 3. TYPICALRADIATOR-COOLEDSETCONTROLPANEL
FieldCircuitBreaker:Providesgeneratorexciterand
regulatorprotectionfromoverheating in theevent of
certainfailuremodes of the generator,exciter and
voltageregulator.
OilPressureGauge:Indicatespressure of lubricating
oil in engine(wired toa sensorunitlocated onthe
engine).
WaterTemperatureGauge:Indicatestemperature of
circulatingcoolant in engine.(Wired to a sensorunit
located onthe engine.)
CrankingLimiter:Thermallyactuateddevicelimits
crankingtime to between 45 and 90 secondsdepen-
ding on the ambienttemperature. Red pushbutton
pops outand cannot be resetuntil one minute has
elapsed.
ACVoltmeter:IndicatesACgeneratoroutputvoltage.
Voltmeter-AmmeterPhaseSelectorSwitch:Selects
thephases of thegeneratoroutput to bemeasured by
the AC voltmeterand AC ammeter.
VoltageAdjustRheostat:Providesapproximately
plus or minus 5% adjustment of the ratedoutput
voltage.
RunningTimeMeter:Registers the totalnumber of
hours to 1/10th that the unithasrun.Useittokeep a
record for periodicservicing.Time is accumulative;
metercannot be reset.
FrequencyMeter:Indicates the frequency ofthe
generatoroutput in hertz. It can be used to check
enginespeed.(Eachhertzequals 30rpm.)
WarningLights:Fourredindicatorlightsgivewarning
of:
1. Plantfailed to start.
2. Overspeed.
3. Lowoil pressure.
4. Highenginetemperature.
Threeresetpushbuttonspermitrestartingafter trou-
ble is corrected.

LineCircuitBreakers:Protectsgeneratorline
overloads.
VOLTAGE RECONNECTION WITH OP-
TIONALINSTRUMENTS
TheoptionalACinstrumentsonthecontrolpanel
(suchasvoltmeters,ammeters,andrunningtime
meters)areinstalledforusewithspecificnameplate
voltages.Controlcomponentsmayhavetobechang-
edtomatchnewcurrentratingswhenfieldreconnec-
tionforothervoltagecodesorvoltagesaremade.
ContactyourOnanServiceCenterforre-
quiredinstrumentchanges,newwiring
diagrams,properspecificationnumber,andvoltagebeforeattemp-
tingtore-connecta generatorwithinstrumentsonthecontrol
panel.