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.

INSTALLATION
GENERAL
Installationsmustbeconsideredindividually.Use
theseinstructionsasa generalguide.Meet
regulationsoflocalbuildingcodes,fireordinances,
etc.,whichmayaffectinstallationdetails.SeeFigure
4.
Installationpointstoconsiderinclude:
1. Levelmountingsurface.
2. Adequatecoolingair.
3.Adequatefreshinductionair.
4. Dischargeofcirculatedair.
5.Dischargeofexhaustgases.
6.Electricalconnections.
7.Fuelconnections.
8.Accessibilityforoperationandservicing.
9.Vibrationisolation.
10. Noiselevels.
LOCATION
Providea locationthatisprotectedfromtheweather
andisdry,clean,dustfreeandwellventilated.If
practical, installinsidea heatedbuildingforprotec-
tionfromextremesinweatherconditions.
Theairdischargesideofsetrequires3 inches
clearancefromwalltopermitsettorockonits
mounts;atleast24inchesclearanceisrequired
aroundallothersidesforserviceaccessibility.
MOUNTING
Apermanentinstallationneedsa sturdy,levelmoun-
tingbaseofconcrete,heavywoodorstructuralsteel,
preferablyraisedtoaidoilchangingandoperation.
Setmaybeboltedinpositionif desired. Allowatleast
24inchclearanceonallsidesofthesetfor con-
venienceinservicing.
Mobileapplications(asintrucksortrailers)mustbe
securelybolteddowntopreventshiftingintransit.
Extrasupportforthevehicleflooringmaybe
necessary.Onallinstallations,carefullyassemblethe
mountingcushions,washersandspacerbushing.
Thespacerbushingpreventscompressionofthe
snubber(upperrubbercushion).Placethecushions
undertheengineandgeneratormountingfeet,using
cushionswithhighernumber(partnumberisshown
oncushion)ongenerator(heavier)end.Spacethe
7/16-inchdiametermountingboltsinfloororbase
withdistancesbetweenholecentersasfollows:
Engineend— 11inches;generatorend— 10-1/2
inches;andengine-to-generator— 21inches.
Besurethereisatleast 1/2-inch clearance
betweenoilfilterandendofmountingboltto
avoidpuncturingthefilter.
VENTILATION
Generatorsetscreatea considerableamountofheat
whichmustberemovedbyproperventilation.Out-
doorinstallationcanrelyonnaturalaircirculation,
butmobileandindoorinstallationsneedproperly
sizedandpositionedventsfortherequiredairflow.
SeeSpecificationsforairrequirementsat1800rpm.
Coolingairtravelsfromtherearofthesettothefront
end. Locatetheroomorcompartmentairinletwhere
mostconvenient,preferablytotherearoftheset.The
inletopeningshouldbeatleastaslargeasthe
radiatorarea.
Engineheatisremovedbya pusherfanwhichblows
coolingairoutthroughthefrontoftheradiator.The
coolingairoutletshouldbedirectlyinfrontofthe
radiatorandascloseasispractical.Theopeningsize
shouldbeatleastaslargeastheradiatorarea.A duct
ofcanvasorsheetmetalmaybeusedbetweenthe
radiatorandtheairoutletopening.Ductsprevent
recirculationofheatedair.
Generatorcoolingairisdischargedfromtheengine-
to-generator-adapterontheleftsideoftheengine.
In coldweathera meansofrestrictingtheairflowcan
beprovidedtokeeptheroomorcompartment
temperatureata normalpoint.
Oncitywatercooledsets,theconventionalradiatoris
notusedanda constantwaterflowcoolstheengine.
Ventilationisseldoma problem,butsufficientair
movementandfreshairmustbeavailabletoproperly
coolthegeneratorandsupportcombustioninthe
engine.Forsmallcompartments,a ductlargerthan
thegeneratoroutletopeningisrecommendedto
removeheatedairfromthegeneratortotheoutside.
Limitbendsanduseradiustypeelbowswhere
needed. A large,wellventilatedcompartmentorroom
doesnotrequirea hotairduct.Watercooledexhaust
manifoldsarerecommended.
CITY WATER COOLING (OPTIONAL)
Connectionsontheengineare3/8-inchpipe.A
solenoidshut-offvalveanda lockshieldsupplyvalve
arefurnishedbutnotinstalled.Thesolenoidvalveis
coordinatedwiththeenginecontroltoshutoffthe
watersupplywhensetisnotinuse.
Thelockshieldvalveismanuallyadjustedtocontrol
waterrate-of-flowforpropercoolingwitha minimum
flowofwater.Finaladjustmentshouldbemadeunder
themaximumloadthesetwillcarrywiththeengine
thoroughlywarmedupandwatertemperature
stabilized. RefertoSpecificationsforwaterflowdata.

INCOMINGSERVICE AUTOMATICLOADTRANSFERSWITCH
EXHAUSTLINE
(SEEINSERT)
HEATEDAIROUT•
lj|COOLAIRIN
55ORI 10GAL.
FUELTANK
CONNECT
FUELRETURN
LINEHERE
FLEXIBLELINE)
PUMP
SINGLETHIMBLEDIAMETER12
LARGERORDOUBLE
VENTILATEDTHIMBLE
DIAMETER6 " LARGER
.THANEXHAUSTLINE
HOLESINEND
INNERSLEEVE
EXHAUST LINE PASSING THROUGH
|l WALI ORPARTITION
IFEXHAUSTLINEMUSTBEPITCHED
UPWARDCONSTRUCTA TRAPOFPIPE
SITTINGSATPOINTOFRISE
AVOIDSHARPBENDS
1
DRAINCONDENSATIONTRAP
PERIODICALLY
—CARRIAGEBOLT
SQUARENUT
LOCKWASHER
FLATWASHER
SNUBBER
GENERATOROR
OILBASEMOUNTING
FOOT
CUSHION
MOUNTINGSPACER
BUSHING
LATWASHER
FIGURE4.TYPICALINSTALLATION
10

HEAT EXCHANGER COOLING (OP-
TIONAL)
Thisisa closedcoolingsystemcommonlyreferredto
asfreshwatercooling,Figure5.Watercirculated
throughtheengineistermedfreshwater,hotwater,
jacketedwater,etc.Watercirculatedthroughtheheat
exchangeronlyiscalledrawwater,seawater,cold
water,dischargedwater,citywater,etc.Thissystem
(withanti-freezecoolant)isrecommendedwhere
freezinghazardsexistorwheretheownerwantsto
preventsaltwaterproblems.
Twoconditionsprevail:(1)Factoryinstalledheat
exchanger,and(2)CustomerinstalledOnanheat
exchangerkit.GetdetailsfromOnan.
Usea centrifugalmetalimpellerwaterpump(Ober-
dorfer1-GP,orequal)inthehotwaterside.Driveit
witha beltfromtheenginepowertakeoff.
Useanexpansiontankinthehotwaterside.
Fillclosedcoolingsystemswithclean,alkali-free
water,totheproperlevelintheexpansiontank.Add
anapprovedrustinhibitortothecoolant.Ifthe
coolantisanti-freeze,testitperiodically.
EXHAUST
Pipeexhaustgasesoutsideanyenclosure.The
exhaustoutletis 1-1/2-inch pipesize.Locatethe
exhaustoutletfarfromtheairinlettoavoidgasesre-
enteringtheenclosure.Useflexibletubingtoconnect
betweentheengineexhaustandanyrigidpipe
extension. Shieldthelineifitpassesthrougha
combustible wall, Figure4.Ifbendsarenecessary,
usesweeping(largeradius)elbows.Ifpitchedup-
wardinstalla condensationtrapatpointofrise.
Increaseonepipesizeforeachadditional10feetin
length.
FUEL TANKAND LINES
Wherea separatefueltankfsused,installthefueltank
sothatthebottomofthetankwillbelessthan8 feet
belowthefuelpump.Thetopofthefuelsupplytank
mustbebelowthefuelpumptopreventsiphoningifa
systemleakoccurs.Forservicingputa valveatthe
tank.Wherethefuelisshared,donotconnecttoan
existinglineata pointabovethefuelsupplylevel.This
avoidsstarvingtheengine.
Iffuelliftexceeds6 feet,installanauxiliaryelectric
fuelpumpnearthefuelsupply.SeeWiringDiagram
forinstallationconnection.
THERMOSTAT
HOUSIN BLEEDERVALVE
WATERMANIFOLD-EXCHANGER
EXHAUST
MANIFOLD
\
CITYWATER
INLET
RAWWATER
DISCHARGE
REARCYLINDER
BLOCKCONNECTION
NFFONTCYLINDER
BLOCS' CONNECTION
CENTRIFUGALPUMP
(FRESHWATER)
_- RAWWATER
'T-T^ --xyvwFRESHWATfi R iMCLOSEDSYSTEM
/—/
11
li Bl
siji'V* \3
li Bl
siji'V* \3
\) /nfl j
li Bl
siji'V* \3 Of
"^"-HEATEXCHANGER
BRACKET
EE? Ifo^iS
Of
"^"-HEATEXCHANGER
BRACKET
FIGURE5. HEATEXCHANGERPLUMBING
11

Useapprovedflexiblefuellinenexttotheengine.
Dieselenginesrequirea fuelsupplylineanda
separatefuelreturnline.Installthefuelsupplyline
fromthesupplytanktotheinvertedflaremaleelbow
mountedintheinletofthefuelpump.Installthefuel
returnlinefromtheinjectionpumpbleedervalveto
thesupplytank,Figure6.
LOAD
SEN.
NOZZLES-
FUELRETURN
LINES(SHADED)
CONNECTFUEL
RETURNLINE
HERE(FLEXIBLE)
INJECTION
PUMP
FIGURE6.FUELSYSTEM
Donotusegalvanizedlines,fittings,orfueltanksin
thefuelsystem.Carefullycleanallfuelsystem
componentsbeforeputtingthesetintooperation.
Anydirtorcontaminationmaycausemajordamage
tothefuelinjectionsystem.
OIL DRAIN
Extendtosuitinstallation.Oilbasehasa 1/2inchpipe
tappedhole.
ELECTRICAL CONNECTIONS
Thenameplateonthegeneratorsetshowsthe
electricaloutputratingofthegeneratorinwatts,volts,
andhertz.Thewiringdiagram,shippedwiththe
generatorset,showstheelectricalcircuitsand con-
nectionsneededduringinstallation.
Allelectricalconnectionsshouldbedonebya
qualifiedservicemanorelectriciantomeettheelec-
tricalcoderequirementsinyourarea.
LOAD WIRES
Thecontrolbox(junctionbox)hasknockoutsec-
tionstoaccommodateloadwires.Useflexible con-
duitandstrandedloadwiresnearthesettoabsorb
vibration.. Usesufficientlylargeinsulatedwires.Strip
insulationfromwireendsasnecessaryforclean
connections.Connecteachloadwiretotheproper
generatoroutputleadinsidethesetbox.Insulatebare
endsofungroundedwires.Useboltprovidedon
controlboxtoconnectthegeneratorgroundleadand
NOTE: SHOWNWITHLINECONNECTEDTOLOAD.
FIGURE7. LOADTRANSFERSWITCH
loadwire.Installa fusedmainswitch(orcircuit
breaker)betweenthegeneratorand load. Ifa test-run
indicateswrongrotationof3 phasemotorsintheload
circuit,switchtheconnectionsatanytwogenerator
terminals.
Standby:Iftheinstallationisforstandbyservice,
installa double-throwtransferswitch(eithermanual
orautomatictype)topreventfeedinggenerator
outputintothenormalpowersourcelinesandtoalso
preventcommercialpowerandgeneratoroutputfrom
beingconnectedtotheloadatthesametime.
Instructionsforconnectinganautomaticload
transferswitchisincludedwithsuchequipment.See
Figure7.
BalanceAllLoads:Dividetheloadsequallybetween
outputleads.Currentloadsforanyoneoutputlead
mustnotexceednameplaterating.Overloadingcan
damagethegeneratorwindings.
SinglePhaseLoadsonThreePhaseGenerators:Any
combinationofsinglephaseandthreephaseloading
canbeusedatthesametimeaslongasthecurrentfor
anyoutputleaddoesnotexceedthegenerator
nameplaterating.
OutputLeadMarkings:Leadsonrevolvingfield
generatorsaremarkedT1,T2,etc.Theseidentifying
marksalsoappearonthewiringdiagram.
SWITCHBOARD
Awallmountedswitchboardcontainingammeters,a
voltmeter,andcircuitbreakersisoptional.When
used, thefollowingconnectionsapply:
1. Connectoneungrounded(hot)generatorleadto
theunusedterminaloneachammeter.
2. Connectthegeneratorleadandloadwireswhich
aretobegroundedtothegroundstudonthe
switchboard.
3.Connectoneungrounded(hot)loadwiretothe
unusedterminaloneachcircuitbreaker.
4. Onsetsthatgeneratemorethanonevoltage
(example:120/240),thevoltmetershouldbe
wiredtoindicatethehigherofthetwovoltages.
12

GENERATORCONNECTION
SCHEMATICDIAGRAM
LOADTO
GENERATORCONNECTION
WIRINGDIAGRAM
CONNECTXITOVR21-5FORSOHERTZANDX1
TOVR21-6FOR60HERTZGENERATORS.
3C
53C
120/240
120/240
II 5/230
II0/220
60
VI
V2
V3
fri—
L,
r—4LO
-L2 TlT2T3T4 TlT3T2T4
LlLOL2
TlT2T3T4
18
SIS
120/208
127/220
139/240
I10/190
II 5/200
120/208
127/220
VI
V2
V4
VI
V2
V3
V4
LO Ll* L2L3
T4T5T6TIOTlITI2TlT7T2T8T3T9
18
518
240/416
254/440
277/480
220/380
230/400
240/416
254/440
VI
V2
V4
VI
V2
V3
V4
L2
TIOTIIT12TPT4T7T2TST8T3T6T9
18
518
120/240
I10/220
I15/230
120/240
60 VI
VI
V2
V3
LOL2
T4T7T2'TI0T5T8T3TIIT6T9TlT 12
18
518
120/240
I10/220
I15/230
120/240
60 VI
VI
V2
V3 T2T4T7TI2TlT6T3T5T8TIOT9Til
18
518
120
IIO
115
120
60 VI
TlT7T6TI2T3T9T5TI I T4TIOT2T8
9X 347/600 LlL2L3LO
TlT2T3TO
FIGURE 8. GENERATOR WIRINGANOCONNECTIONDIAGRAMS
13

UNGROUNDED LOAD
WIRE (BLACK)
120V.
GROUNDED LOAD
OT1.T3g
(JOIN)2
UNGROUNDED LOAD
"|WIRE (BLACK)
O Tl
240
V.
Z <Q
OT2.T35S<
WIRE (WHITE)
^T^O T2,T4O
—L_ rmn.)A KIr>r\D
•^•(JOINANDGROUND)
Useaboveconnectionifallloadsaresamevoltage.
UNGROUNDED LOADWIRE (BLACK)
GROUNDED LOAD^
-j^O T 4
WIRE (WHITE).
120V.
240V.—|
120 V.
i
GROUNDED L O A D WIR E (WH ITE) T2,T3o
UNGROUNDED LOADWIRE (BLACK)
-O T4
Only1/2plantcapacityisavailableoneach120voltcircuit.
IPhase,ReconnectibleGenerator(SeeText)(60cyclemodelhascode-3C;
gives2 wireor3 wireservice)
OL
O «/>
<Q
«>£<
Uiui
Z-«
UJ
o
3 PHASE
NAMEPLATE
HIGHER
VOLTAGE
UNGROUNDED LOADWIRE (BLACK)
•O Tl
UNGROUNDED LOADWIRE (BLACK)
,.UNGROUNDEDLOADWIRE (BLACK)^.
rrT
OT2
T3
tt ^GROUNDEDLOADWIRE(WHITE)
OT0
<
ee.
O
<
ex.
UJ
Z
UJ
o
A = N ameplatelowervoltage,!phasecircuit
B = Namepjatehighervoltage,1phasecircuit
3Phase,4Wire,WyeConnectedGenerator(60cyclemodelhascode-4for120/208volt;orcode-4X
for277/480volt;orcode-9Xfor347/600volt)' . .
3 PHASE
NAMEPLATE
HIGHER
VOLTAGE
NEUTRAL LOADWIRENORMALLYUNGROUNDED^ £
T t ' ToISTHE RENTER TAP^ *~'T0<
BETWEEN TlA NOT?"
A A
H-
B
X
UNGROUNDED LOADWIRE (BLACK)
•r UNGROUNDEDLOADWIRE (BLACK)
B B
-O Tl«
O
-OT2<
UJ
Z
-o
UNGROUNDED LOADWIRE (BLACK)
A = N a m e piate low ervoltage,lphasecircuit
B = N p mep I ate highervoltage,!phasecircuit
3Phase,4Wire,DeltaConnectedGenerator(60cyclemodelhascode-5Dfor120/240volt)
T3
O
UNGROUNDED LOADWIRE
3 PHASE
NAMEPLATE
VOLTAGE
1 PHASE NAMEPLATE VOLTAGE
UNGROUNDED LOADWIRE
> 1 PHASE NAMEPLATE VOLTAGE
UNGROUNDED LOADWIRE
3Phase,3 WireGenerator(60cyclemodelhascode-5for240volt)
OTl
-O T2
-O T3
BL
o
<Q
£*<
UJUJ
Ui
o
FIGURE 9.LOADWIRECONNECTIONS
14

RECONNECTIBLEGENERATORS, BEGIN
SPEC AA
Thefactoryshipsallspecialordersetswithin-
strumentsonthecontrolpanelscompletelywiredfor
thevoltagecodeorvoltagespecifiedonthe
customerspurchaseorder.Standardsetswithout
instrumentsareshippedwiththeT'-T4orT1-T'2
outputleadsseparatedintheoutputbox.These
singlephaseandbroadrangegeneratorsareconnec-
tibleorlaterreconnectibletoprovideanyofthe
outputvoltagesshowninFigure8•
Code3Cor53CReconnectibleGenerators:The
singlephase,60and50Hertzgeneratorshaveoutput
leadsT',T2,T3,andT4availableformakingthesingle
phasevoltageandloadconnectionsshowninFigure
8attheinstallationsite.Groundingprocedureshould
complywithlocalcodes.
Code18Ror518RReconnectibleGenerators:The
threephase,broadrange,60and50Hertz12lead
generatorshaveoutputleadsT1throughT12available
formakingseveralsingleandthreephasevoltage
loadconnectionsshowninFigure8.Grounding
procedureshouldcomplywithlocalcodes.
Whenconnectingtheoutputleads,besuretoconnectjumperWIO
onthevoltageregulatorprintedcircuitboardbetweenterminalV4
(common)andV,V2,orV3aslistedonthereconnectiondiagram.
Abroadrangegeneratoriscapableofgeneratingnumerous
differentoufput.voltagesasindicatedbythereconnectiondiagram.
Code9XGenerators:Thesespecialorderthree
phase,60Hertz,4 wire,generatorsareprewiredatthe
factorytoprovide347/600VAC.OutputleadsT1,T2,
T3,andT0areavailableforconnectiontotheload
wires. Seeconnectiondiagram.Grounding
procedureshouldcomplywithlocalelectricalcodes.
GENERATORS PRIOR TO SPEC AA
Revolvingfieldgenerators,usedwiththeRDJFseries
priortoSpecAA,havefourleads.Connectionsfor
thesegeneratorsareshowninFigure9.
ReconnectibleSinglePhaseGenerators:Code3C
models,suchasRDJF-3Carereconnectibleforuse
as120/240volt3 wire;120volttwowire;or240volt2
wireunits(Figure8)exceptwhenoptionallyequipped
witha meterpanel.
DeltaGenerators:Onthesegenerators,T0isthe
centertapbetweenT1andT2;T0isnormallynot
groundedbutmaybegroundedifrequired.
Grounding:A number8 orlargerwireshouldbeused
toconnectthegeneratorhousingtoa rodorpipethat
penetratesintomoistearth.Ifa solderlessconnector
isnotprovidedonthegenerator,connecttheground
wireatthebatterygroundstudontheengine.
STARTINGMOTOR
y
BATTERY
POSITIVE
A625
BATTERY
NEGATIVE
12. V.BATTERY
CABLESIZE
000
000 0000
4ft. 5ft. 7ft. 9ft. IIft.
I 4 ft.
FIGURE10.BATTERYCONNECTION
BATTERY CONNECTIONS
Thebatteryis.connectedfornegative(-)ground,
Figure10.Besureallbatteryconnectionsaresecure.
Batterypolaritymustagreewithth^eetifieMocated
inthecontrolbox.Ifbatteryground'm.dstbechanged,
reversetherectifierconnectioninthecontrolbox/
f^erseii "/
CAUTION{ Ifbatterypolarityiswiwg,damage wiM occur
within3 minutestobUe,.stoppecfor5 seconds
whilerunning.Alternatorwindingswillbedamagedalmostinstant-
lyifbatterychargingcircuitisshortedbetweenresistor R21 andthe
B1endofthechargingwinding.
SeeSpecificationsforminimum12voltbatteryre-
quirements.Connectbatterypositive(+)tostarter
engagingsolenoidterminalpost,Figure9.Connect
batterynegative(-)toa goodgroundontheengine.
Setsmaybeequippedfor24voltcrankingandbattery
chargingcircuit.Batteryconnectionsaresimilarto12
voltconnections.Providetwo12voltbatteries con-
nectedinseries(onebatterynegativetotheother
batterypositive).
OPTIONAL ALARM
TheGNDterminalontheremotecontrolterminal
blockisfora customersuppliedalarmata remote
locationtowarnofemergencyshutdown.Referto
WiringDiagramforpropervoltages.
15

GND
REMOTECONTROL
TERMINALBLOCK
ATPLANT
WIRE
SIZE DISTANCE
#18 to 900ft.
#16 to
1500ft.
#14 to2400 ft.
#12 to3700 ft.
11MOMENTARYCONTACT
SWITCH
FRONT
Rev
FIGURE11.REMOTECONTROLSWITCH
REMOTESTART-STOP SWITCH(Optional)
Forremotecontrolstartingandstopping,use2-wires
toconnect the remoteswitchsingle-poledouble-
throw,momentarycontact(center-offtype), tothe
terminalblockmarkedB+andremote in control box
usingwiresizes as listed in Figure11.
16

OPERATION
PRE-STARTING
Preparationsfortheinitialandeachadditionalstar-
tingoperationshouldincludecarefulchecksofthe
oil, fuel, cooling,andelectricalsystems.Thecylinder
airhousingdoorshouldbeclosedwithallairshrouds
inplace.
Beforegeneratorsetisputinoperation,checkall
componentsformechanicalsecurity.Ifanabnormal
condition, defectivepart,oroperatingdifficultyis
detected, repairorserviceasrequired.Thegenerator
setshouldbekeptfreeofdust,dirt,andspilledoilor
fuel. Besureproperoperatingprocedureisfollowed.
CrankcaseOil:UseanoilwiththeAPIdesignation
CD/SDorCD/SE.However,toreduceoilconsump-
tiontoanormallevelintheshortesttimepossibleona
neworrebuiltengine,useCCoilforthefirstfillonly
(50hours).Thenusetherecommendedoilonly.
SelectthecorrectSAEgradeoilbyreferringtothe
following:
Above30° F SAE30
0oFto30° F SAE10Wor5W-30
Below0oFSAE5W-30
Multigradeoilsarerecommendedfortemperatureof
30° F andbelow,buttheyarenotrecommendedfor
temperaturesabove30°F.Whenaddingoilbetween
oilchanges,itispreferabletousethesamebrandas
variousbrandsofoilmaynotbecompatiblewhen
mixedtogether.
RecommendedFuel:Althoughnumber2 dieselfuel
givesthebesteconomyformostoperating con-
ditions,number1 dieselfuelcanbeused:
1. Whenambienttemperaturesarebelow32°F;
2. Duringlongperiodsoflightengine load; or,
3.Ifpreferredbyuser.
Uselowsulfurcontentfuelhavingapourpoint(ability
tofilter)ofatleast10oFbelowthelowestexpected
temperature.Keepthefuelcleanandprotectedfrom
adverseweather.Leavesomeroomforexpansion
whenfillingthefueltank.
r^^^^^^"? Duetotheprecisetolerancesofdieselinjec-
L^i^^~s^^*Jz tionsystems,itisextremelyimportantthefuel
bekeptclean.Dirtinthesystemcancauseseveredamagetoboth
theinjectionpumpandtheinjectionnozzles.
Bleedairfromfuelsystemasfollows:Disconnectthe
fuelreturnline.SeeFigure12.Operatethehand
primingleverondiaphragmtypefueltransferpump
untiltherearenoairbubblesinfuelflowingfromthe
fuelreturnlinefitting.Thenconnectthefuelreturn
line.
WORKTRANSFERPUMP
PRIMINGLEVERUNTIL
FUELFLOWSFROMRE-
TURNLINEFITTINGOF
INJECTIONPUMP
ALWAYSRETURN
PRIMERLEVERTO
LOWESTPOSITION
FIGURE12.PRIMINGFUELSYSTEM
Ifthecamshaft'spumplobeisup,crankengineonerevolutionto
permithandpriming.Whenfinished,returnprimingleverinward
(disengagedposition)topermitnormalpumpoperation.
Radiator:SeeSpecificationsforwatercapacity.
Checktoseethattheradiatordrainvalveisclosed
andcylinderblockdrainplugistight.Filltheradiator
withclean,soft(alkalifree)watersuchasrainwater.
Theuseofa goodrustandscaleinhibitoris
recommended.
Ifthesetwillbeexposedtofreezingtemperatures,
usea standardanti-freezesolution.Usethecorrect
proportionofanti-freezeasrecommendedbythe
anti-freezemanufacturer,toprotecttoatleast10oF
belowthelowestexpectedtemperature.
ACGenerator:Periodicinspections,thatcoincide
withengineoilchangeswillensuregoodperfor-
mance.
STARTING SEQUENCE
Thestartingandstopping(Figure13)sequence
showsthemanual,mechanical,andelectricalevents
requiredforsatisfactorystart,run,andstopcycles.
PRE-HEATING AND STARTING
Extremesinstartingtemperaturesmayrequiread-
ditionalpreheating.Ifenginefailstostartquickly,rest
engineseveralsecondsandrepeatstartingsequence
applyingpreheatfora longerintervalusingheater
switch.
Ifthesetcontrolhasa resetbutton,pushittoreset
onlyaftera shutdownresultingfromoilpressure
failureoccurs.Findthecausebeforerestartingthe
engine.
Topreventfalsestarts,holdonstartswitchuntilthecentrifugal
switchautomaticallydisengagesstartermotor.
17

OPTIONALITEMS
L.O.P.= LOWOILPRESSURESWITCH
H.W.T.= HISHWATERTEMP.
SWITCH IS
O.S.= OVERSPEED SWITCH -r.
FIGURE13.OPERATINGCYCLE
PushtheRUN-STOPswitchtoitsRUNposition
(enginewillpreheatandcrankinabout20seconds).
Afterenginestarts,seethattheoilpressuregauge
readsatleast20psi.Reliefvalvepressureisnot
adjustable.
Whenstartingsetfroma remotestation,theswitchontheset
controlmustbeinitsREMOTEposition.
Whenengine , comesuptospeed,crankingwill
automaticallystopthroughthecentrifugalswitchand
start-disconnectrelay.Iftheenginefailstostartin
from45to120seconds,thecrankinglimiterwilltrip
andcrankingwillstop.Ifthisoccursontheinitialstart
orfromotherconditionssuchasoutof fuel, remedy
thecause.Waitoneminutebeforeresettingthe
crankinglimiterandreattemptingtostart.
Makesurecentrifugalswitchclosesdurjngspeed
buildup(about900rpm's).
Donotapplyovervoltagetothestarting
circuitatanytime.Overvoltagewilldestroy
theglowplugsandairheaterin2 to3 seconds.Ifitbecomes'
necessarytouseanadditionalsourceofpowertostarttheset—
usea 12voltbatteryconnectedinparallel.
AUTOMATIC STARTING AND STOPPING
Separatecontrolsmaybeusedforautomaticstart
andstop,butmustprovideenginepreheating.
Theautomaticcontrolhasa timedelayrelayto
preheatglowplugsandthemanifoldheaterforabout
20secondsbeforecrankingoccurs.Thetimedelay
relaypreventsimmediateengagementofthestarterin
casetheloadisreappliedbeforetheenginestops.
STOPPING
1. Pushstart-stopswitchtostopposition.
2. Releaseswitchwhensetstops.Ifstopcircuitfails,
closefuelvalve.
APPLYING LOAD
Ifpracticable,allowsettowarmupbeforeconnecting
aheavy load. Continuousgeneratoroverloadingmay
causehighoperatingtemperaturesthatcandamage
thewindings.Thegeneratorcansafelyhandlean
overloadtemporarily,butfornormaloperation,keep
theloadwithinnameplaterating.Theexhaustsystem
mayformcarbondepositsduringoperationatlight
loads,; applyfullloadoccasionallybeforeshut-down
topreventexcessivecarbonaccumulations.
Trytoconnecttheloadinstepsinsteadoffullloadat
onetime.Mostinstallationsusea lineswitchthat
mustbeclosedtoconnecta portionofthe load.
18