ONAN 100 DVC 100.0DVC 100KW Diesel Generator Engine Workshop Manual

ONAN 100 DVC 100.0DVC 100KW Diesel Generator Engine Workshop Manual

Diesel GenSets

McGraw-EDISON ONAN 100 DVC 100.0DVC 100KW Diesel Generator Engine Parts Contact phone: 269 673 1638 Email: engineparts2@gmail.com www.Diesel-Generator-Engine-Parts.com

Table of Contents

TABLE OF CONTENTS ............................................... .......... ............. . 1 Onan Komatsu 0665T Adjusting Valve Clearance, Valve Lash Specifications.........................................E2 Onan Komatsu 0665T Head Bolt Torque Value, Head Bolt TighteningSequence.....................................E3 Onan Komatsu 0665T Engine Reassembly Bolt Torque Values.................................................................E4 Onan Komatsu 0665T Engine Maintenance Standards...............................................................................E5 INTRODUCTION ............................................................................. 2 About This Manual........................................·.................................. 2 How to Obtain Service ...................................................................... 2 SPECIFICATIONS ............................................................................ 3 DVC ......................................................................................... 3 DVD ......................................................................................... 4 DVE ......................................................................................... 4 OPERATION ................................................................................. 5 General .................................................................................... 5 Prestart Check .............................................................................. 5 Control Panel............................................................................... 5 Control Panel Interior ....................................................................... 7 Starting Procedure...................................... ................................... 9 Stopping .............................................. . ................................... 9 Operating Recommendations............................ ................................... 9 Out-of-Service Protection .................................................................. 10 Troubleshooting ........................................................................... 10 MAINTENANCE ............................................................................. 14 Maintenance Schedule ..................................................................... 14 Set Inspection .................................................................... ......... 15 Lubrication System ........................................................................ 15 Fuel System ............................................................................... 18 Cooling System............................................................................ 19 Batteries .................................................................................. 21 Alternator and Fan Belt..................................................................... 21 AC Generator ............................................................................. 21 Air Cleaner ................................................................................ 22 Turbocharger.............................................................................. 23 Valve Clearances .......................................................................... 23 Vibration Damper .......................................................................... 23 Onan Komatsu 0665T Adjusting Valve Clearance, Valve Lash Specifications...................24 Onan Komatsu 0665T Head Bolt Torque Value, Head Bolt TighteningSequence...............25 Onan Komatsu 0665T Engine Reassembly Bolt Torque Values................................26

Onan Komatsu 0665T Diesel Generator Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

ONAN KOMATSU 0665T

ADJUSTING VALVE CLEARANCE METHOD FOR ADJUSTING VALVE CLEARANCE 1.

Remove cylinder head cover.

2.

Rotate the crankshaft in the normal direction to align pointer (3) with the 1.6 TOP mark on vibra­ tion damper (2). When rotating, check the move­ ment of the intake valve of No. 6 cylinder. Set with No. 1 cylinder at compression top dead center.

When No. 1 cylinder is at compression top dead center, the intake valve of No. 6 cylinder can move (is open).

* 3.

When No. 1 cylinder is at compression top dead center, adjust the valves marked•·

4.

Then rotate the crankshaft one turn in the normal direction, and adjust the valves marked o.

t

*

Adjust the valves marked•· 1

Cylinder No. Intake valve Exhaust valve

*

5.

To adjust, loosen locknut (8) of adjustment screw (7). Then insert feeler gauge A between valve stem (6) and rocker arm (5), and turn adjustment screw until clearance is a sliding fit. a: Valve clearance Intake valve lash clearance 0.25MM or .010" Exhaust valve lash clearance 0.45MM or .017"

Tighten locknut to hold adjustment screw in posi­ tion.

*

*

Locknut torque value: 47 Ft Lbs or 6.5 kgfm 'After adjusting No. 1 cylinder at compression top dead center, it is also possible to turn the crank­ ° shaft 120 each time and adjust the clearances of the intake and exhaust valves of each cylinder according to the firing order.

• Firing order: 1-5-3-6-2-4 After tightening the locknut, check the clearance again.

E2

a

•

• • 0

6

5

4

3

2

•

0 0

•

6

5

•

0

0 0

8

ONAN KOMATSU 0665T Head Bolt Torque Value, Head Bolt Tightening Sequence

1)

Install head gasket ( 1) with word TOP facing up.

Be careful not to damage the bottom face of the cylinder head and the mounting surface of the cylinder block. Also check that there is no dust or dirt on these surface.

*

New Head Bolt Set part number 6136-S1-1622 Install cylinder head (21.

2)

Coat thread of mounting bolts with anti-friction

3)

compound or engine oil, and then tighten bolts as shown in diagram.

Head Bolt Torque Value in Ft Lbs Procedure

with anti-friction compound

with engine oil

Step 1

65

65

Step 2

94

94

Step3

139

144

*

Tightening order of cylinder head bolt

Center

__,___ Front 1-�

�

�--_._-

----+---+----<Rear

20

Onan Komatsu 0665T Diesel Generator Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

E3

ONAN KOMATSU 0665T Engine Reassembly Bolt Torque Values - threads lightly oiled

Main Bearing Cap Bolts Step 1 - 51 Ft Lbs Step 2 - 145 Ft Lbs Step 3 - Loosen Step 4 - 101 Ft Lbs Step 5 - 145 Ft Lbs Connecting Rod Bearing Cap Bolts Step 1 - 43 Ft Lbs Step 2 - 80 Ft Lbs Step 3 - Loosen Step 4 - 43 Ft Lbs Step 5 - 81 Ft Lbs Flywheel Housing Bolts - 80 Ft Lbs Flywheel to Crankshaft Bolts - Step 1 - 65 Ft Lbs, Step 2 - 130 Ft Lbs Timing Idler Gear Thrust Plate Bolts - 80 Ft Lbs Front Crankshaft Pulley Bolts - 275 Ft Lbs Oil Pan Mounting Bolts - 180 Ft Lbs Head Bolts - Step 1 - 65 Ft Lbs, Step 2 - 94 Ft Lbs, Step 3 - 144 Ft Lbs, Head Bolt Tightening sequence:

Injector Bolts: 12.5 Ft Lbs Injection Pump Coupling Bolts: 23.5 Ft Lbs Turbocharger Back Plate Mounting Bolts: 6.87 Ft Lbs Turbocharger Impellor Lock Nut: 1.59 Ft Lbs + 90 degrees Turbocharger Turbine Housing Mounting Bolts: 12.3 Ft Lbs Turbocharger Charge Air Outlet Housing Bolts: 9.76 Ft Lbs Onan Komatsu 0665T Diesel Generator Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

E4

Onan Komatsu 0665T Engine Maintenance Standards

ENGINE BODY CYLINDER HEAD

Center

*Tightening order of head mounting bolt

Unit· mm No.

Check item

1

Distortion of cylinder head mounting surface

2

Protrusions of nozzles

Tittening torque of cy inder head mounting bolts 3

4

( Coat the thread areas with molybdenum disulfide or engine oil) Tightenin torque of nozzle hoP,der mounting bolt

Remedy

Criteria Tolerance

Repair limit

0- 0.09

0.12

Engine No.

Standard

10001 - 49999 50001 -

0.79 - 1.71 1.29 - 2.21

Repair by grinding or replace

Replace nozzle sleeves

When coat with engine oil

When coat with MoS 2

Sequence

Target value (kgm)

Range (kgm)

Target value (kgm)

Range (kgm)

1st 2nd 3rd

9 13 18

8-10 12-14 17.5-18.5

9 13 20

8-10 12-14 19.5-20.5

Target value (kgm)

Range (kgm)

1.75

1.5 -2.0

Tighten in sequence as indicated above.

Retighten

CHECKING AND INSPECTION A.

Cracks in the cylinder heads After cleaning, inspect the cylinder heads for cracks By combined use of the water pressure test meth­ od and the penetration flaw detecting method.

By combined use of the hydraulic test method and the magnetic flow detecting method.

Hydraulic test Apply water pressure at 3.5 kg/cm 2 (max.) through one water hole in the top for ten minutes to check for water leak.

During test, be careful not to peep into the cylinder heads to prevent accidental injuries, because there is a possibility of loose plugs and sleeves to pop out of place under excessive water pressure.

E5

B.

Distortion of the cylinder head mounting surface Place a straightedge on the mounting surface in the six positions, shown below, then measure the gap between the edge and the head surface with a thickness gauge.

0 /:'

B'

B

�

C.

0

Protrusion of a nozzle Measure the protrusion of a nozzle at its tip with a dial gauge.

/:',

Onan Komatsu 0665T Engine Maintenance Standards

VALVES AND VALVE GUIDES

5

CHECKING AND INSPECTION A. Amount of valve sinking Place a strightedge on the cylinder head mounting surface and measure the amount of valve sinking with a thickness gauge.

B.

4

2

Abnormal valve conditions Mark the valve seat surface with a pencial at 20 posi­ ° tions and turn it by approximate 10 . Check the surface.

If some marks remain on the surface correct the sur­ face by grinding or lapping the valve to the valve seat.

Unit: mm No.

Valve

Standard size

Tolerance

Repair limit

Intake valve

1.5

±0.24

2.6

Exhaust valve

1.5

±0.28

2.6

Intake and Exhaust valves

0

±0.1

1.1

Engine No.

1

Sinking of valve

1000149999 50001 -

2

3

Thickness valve lip

Standard size

Repair limit

Intake valve

2.10

1.7

Exhaust valve

1.50

1.2

Intake valve

Exhaust valve

Inner dia. of valve guide

10001-49999

Tolerance

Intake valve

10

-0.040 -0.060

Exhaust valve

10

-0.065 -0.085

Intake and Exhaust valves

9

-0.030 -0.045

10001- 49999

Intake and Exhaust valves

10

+-0.025 -0.005

50001-

Intake and Exhaust valves

9

+o.030 +0.010

Standard clearance

Clearance limit

Intake valve

0.035 - 0.085

0.22

Exhaust valve

0.060 - 0.110

0.24

Intake and Exhaust valves

0.040 - 0.075

0.20

Valve

10001- 49999

50001 Bend of valve stem

Standard size

Valve

50001-

Engine No.

Valve stem-to-valve guide clearance

Replace valves.

° 45

60°

Standard Engine No.

4

Replace valve or seat.

Angle of valve seat

Outer dia. of valve stem

Remedy

Criteria

Check item

Repair limit: 0.02 (at 100 mm)

Repair or replace valve or valve seat.

Replace valve.

Replace valve guide.

Replace valve or valve guide.

Replace.

Onan Komatsu 0665T Engine Maintenance Standards

*

Valve spring Engine No. 10001 - 49999: Equal pitch 50001 Unequal pitch

Unit: mm No.

5

Check item

Height of valve guide when knocked in

Free length of valve spring

6 Installed load of valve spring

Criteria

Remedy

Engine No.

Standard

10001 -49999

19.0

±0.2

50001 -

25.9

±0.25

Tolerance

Engine No.

Standard size

10001 -49999

59.4

58.0

50001 -

63.8

62.4

Engine No.

Installed length

10001 -49999

50.1

Repair limit

Standard load 29.0 ± 1.3 kg

50001 Squareness of valve spring

Repair limit: 2

Repair.

°

Repair limit 26.0 kg

Replace valve spring.

Onan Komatsu 0665T Engine Maintenance Standards

ROCKER ARM SHAFT, PUSH-ROD AND TAPPET 4

3

3

5

tssssssssS» 2 2 Unit: mm No.

Check item

O.D. of rocker arm shaft

1

I.D. of rocker arm shaft hole

Clearance between rocker arm shaft and rocker arm

2

Engine No.

Standard size

Tolerance

10001 - 49999

19

-0.010 -0.030

50001 -

19

-0.010 -0.030

10001 - 49999

19

+0;030 +0.010

50001 -

19

+0.020 0

Engine No.

Standard clearance

Clearance limit

10001 - 49999

0.020 - 0.060

0.13

Replace rocker arm shaft

Replace rocker arm

Replace rocker arm shaft or rocker arm

50001 -

Bend of rocker arm shaft

Repair limit: 0.20 (Total indicator reading)

Replace rocker arm shaft

Bend of push-rod

Repair limit: 0.30 (Total indicator reading)

Replace push-rod

Tightening torque of rocker arm adjusting screw locknut

Target value (kgm) 3.15 Engine No.

4

Remedy

Criteria

Valve clearance (when engine is hot or cold)

Valve

Range (kgm)

Standard

Intake

0.35

Exhaust

0.65

10001 - 49999

Tighten

2.8 - 3.5 Tolerance

±0.02 Intake

0.25

Exhaust

0.45

Adjust

50001 -

Standard size O.D. of tappet 5

I.D. of tappet hole Clearance between tappet and tappet hole

Tolerance

18

-0.015 -0.035

18

+o.020 0

Standard clearance

Clearance limit

0.015 - 0.055

0.20

Replace tappet Replace cylinder head Replace tappet or cylinder head

Onan Komatsu 0665T Engine Maintenance Standards

CYLINDER BLOCK

8 Unit: mm No.

1

Che ck item

Distortion of cylinder head mounting surfac:41

I.D. of main bearing mounting hole

2

3

4

5

Tolerance

0 - 0.008 Standard size

I.D. of cam bushing mounting hole

I.D. of cam bushing

Remedy Repair limit

0.12

Correct by grinding or replace

Tolerance

+o.020 0

91

Straightness of mounting hole Roundness of mounting hole I.D.of main bearing mounting hole

I

Criteria

Repair limit:

0.010

Repair limit:

0.005

Standard size

Tolerance

Repair limit

85

+o.130 +o.060

85.16

Standard size

Tolerance

+o.030 0

57.5 Standard size

Tolerance

Repair limit

54.5

+o.070 0

54.78

Replace main bearing cap

Replace main bearing

Repair or replace cylinder block

Replace cam bushing

Onan Komatsu 0665T Engine Maintenance Standards

I I

6

Unit: mm No.

Check item

Criteria Sequence

Target value (kg.ml

1st

7

2nd

6

Tightening torque values of main bearing cap (Coat thread area with oil)

Remedy

20

Range (kg.ml

6-8 19-21

Loosen

0

0

3rd

7

6-8

4th

14

13-15

20

19- 21

5th

I

Tighten

'

7

Tightening torque of oil pan mounting bolts

--

Tightening torque of crank pulley mounting bolt

--

2.5

1.5- 3.5

38

35-41

Uneven mounting surfaces between cylinder block and flywheel housing

Repair limit: 0.13

10

Uneven mounting surfaces between cylinder block and front cover

Repair limit: 0.11

11

Uneven mounting surfaces between cylinder block and front plate

Repair limit: Protrusion of plate: Retreat of plate:

0.04 0.22

Correct and reassemble

Onan Komatsu 0665T Engine Maintenance Standards

CYLINDER LINER

Unit: mm No. 1

Check item

Cylinder liner inner dia.

4

Standard size

Cylindricity

Repair limit: 0.08

105

Standard size

105.20 Replace cylinder liner

Cy Iinder Iiner-to-block interference (counterbore)

Standard interference

Tolerance +0.115 +o.075 Interference limit

0.01 5 - 0.115

0.01

Outer dia. of cylinder liner (counterbore bottom)

Standard size

Tolerance

121

-0.120 -0.170

Outer dia. of cylinder liner (counterbore)

127

Cylinder liner-toblock clearance (counterbore bottom)

Standard clearance: 0.165- 0.280 Standard size

Tolerance -0.010 -0.035

118.7

Cylinder liner-to-block clearance (O-ring)

Standard clearance: 0.010- 0.070

CHECKING AND INSPECTION A.

Repair limit

Tolerance

Roundness

Outer dia. of cylinder liner (O-ring) 5

Replace Iiner or cylinder block

Permissible range: 0.05- 0.13 Difference among cylinders: 0.05 max. +0.035 0 Repair limit: 0.08

2

3

Remedy

Criteria

Protrusion of cylinder liner

B.

I.D. of the cylinder liner Measure the I. D. at the points indicated with a cylinder gauge or an inside micrometer.

Replace cylinder liner or block Replace cylinder line Replace cylinder Iiner or block Replace cylinder liner Replace cylinder liner or block

Protrusion of the cylinder liner Measure the protrusion at 4 points around the cyl­ inder with a dial gauge.

X

Top-

Middle-

y

I

*

Bottom

X'

Where a liner has been reset in place, use a lock plate (1) to hole down the liner flange then tighten the bolts to prevent the liner from being pushed up by the surface pressure on the O-ring, after which, measure the protrusion.

Onan Komatsu 0665T Engine Maintenance Standards

CRANKSHAFT

3

2

4 Unit: mm

No.

1

Criteria

Check item

End play

Remedy

Standard size

Repair limit

0.40

0.140 - 0.315 Standard size

2

0.0.of main journal

Clearance at main journal

85.00

84.86

0.25 U.S.

84.75

84.61

0.50 U.S.

84.50

0.75 U.S.

84.25

84.11

1.00 U.S.

84.00

83.86

3

4

Bend of crankshaft

84.36

Standard clearance

Clearance limit

0.060 - 0.130

0.30

S.T.D.

66

0.25 U.S.

65.75

Tolerance

Correct undersize or replace

Replace main bearing

Repair limit 65.91 65.66

-0.050 -0.070

0.50 U.S.

65.50

0.75 U.S.

65.25

65.16

1.00 U.S.

65.00

64.91

Roundness of crank pin journal Clea ranee at crank pin journal

-0.050 -0.070

Repair limit: 0.020

Standard size

0.0. of crank pin journal

Repair limit

Tolerance

S. T.D.

Roundness of main journal

Replace a thrust bearing or correct oversize

65.41

Correct undersize or replace

Repair limit: 0.020 Standard clearance

Clearance limit

0.040 - 0.105

0.30

Repair limit: 0.09 (Total indicator reading)

Replace connecting rod bearing

Correct undersi ze or replace

Onan Komatsu 0665T Engine Maintenance Standards

CHECKING AND INSPECTION A. Crankshaft end play Before removing the main bearing caps when disassembling, measure the main bearing and play to check for its proper value. After reas­ sembly, measure the end play again.

To measure the end play, use any of the follow­ ing two methods.

Measurement. with a dial gauge Hold a dial gauge vertically against the flange end surface at the rear of the crank­ shaft and take readings of the movement when the crankshaft is shifted back and forth with a crowbar.

B. Bend of the crankshaft •

*

Hold the crankshaft at the center of each end surface on a lather or on a centerless grinder and hold a dial gauge vertically to the hournal at the mid-point of the crankshaft. Then, rotate the crankshaft one revolution, while reading the dial gauge.

Checking the crankshaft for bending with both of its ends supported by V-blocks is not made because of errors due to eccentric wear of the hournals.

C. Clearance at the bearings Main journal After tightening the main cap to a specified torque, measure the I.D. in two prependicular directions (excluding the cut-out), by using a cylinder gauge, and obtain the difference from the corresponding crankshaft bearing O.D. Crank pin journal After tightening the connecting rod cap, measure the I.D. in two perpendicular directions (ex­ cluding the cut-out) and obtain the difference from the corresponding crankshaft bearing O.D. If the clearance exceeds the service limit, replace the bearing.

14FOl8

Onan Komatsu 0665T Engine Maintenance Standards

CAMSHAFT

2

SectionA-A

3

Unit: mm No.

1

Check item

Criteria

Remedy

Standard dimension

Repair limit

0.15-0.35

0.50

Standard size

Tolerance

54.5

-0.080 -0:110

Standard clearance

Clearance limit

0.080-0.180

0.28

End play

O.D. of cam shaft journal 2 Clearance at camshaft journal

3

Bend of camshaft

Replace

Replace cam bushing

Replace

Repair limit: 0.03 (Total indicator reading) Engine

Engine No.

Cam

Standard size

Tolerance

Repair limit

10001 49999

For intake and exhaust

45.91

±0.10

45.41

50001

For intake and exhaust

45.74

±0.10

45.24

1000149999

For intake and exhaust

45.91

±0.10

45.41

For intake

45.82

±0.10

45.32

For exhaust

46.24

±0.10

45.74

Non-Turbo

4

Replace thrust plate

Cam height

Turbo 50001-

Replace

Onan Komatsu 0665T Engine Maintenance Standards

TIMING GEAR

Unit: mm No.

Inspection points A,

B,

Gear backlash

C

O.D. of idler gear shaft

I.D. of idler gear bushing

Remedy

Criteria

Check item

Standard clearance

A.

Crankshaft gear and idler gear

0.105- 0.370

B.

Idler gear and injection pump

0.025- 0.425

C.

camshaft gear and camshaft gear

0.110- 0.410

Standard size

Service limit

Idler gear end play

Replace bushing or gear

Tolerance

44

-0.025 -0.050

44

+o.075 +o.010

Standard clearance

Service limit

0.035 - 0.125

0.20

Standard size

Service Iimit

0.05- 0.21

0.4

1 Clearance between idler gear bushing and shaft

0.6

Replace shaft

Replace bushing

Replace thrust plate

Onan Komatsu 0665T Engine Maintenance Standards

PISTON, PISTON RING, PISTON PIN Engine No. 50001 and up

Engine No. 10001 - 49999

2 3 4

6136F045

Unit: mm No. 1

Check item

Criteria

O.D. of piston

No. Thickness of piston ring

2

3

Width of piston ring groove

Clearance between piston ring and piston ring groove

Piston ring gap

O.D. of piston pin

5

I.D. piston pin hole Clearance between piston pin and piston Weight of piston

Standard size

Tolerance

Repair limit

105

0.160

104.80

Standard size

Tolerance

Inspection point

2

No. 1 ring

3

-0.01 -0.03

3

No. 2 ring

2.5

-0.04 -0.06

4

Oil ring

5

-0.01 -0.03

2

No. 1 ring

3

+0.05 +0.03

3

No. 2 ring

2.5

4

Oil ring

5

No.

4

Remedy

Inspection point

Standard clearance

Replace piston

Replace piston ring

Replace piston

+o.04 +o.02 Clearance limit

2

No. 1 ring

0.04- 0.08

0.15

3

No. 2 ring

0.06 - 0.10

0.17

4

Oil ring

0.03- 0.07

0.15

2

No. 1 ring

0.3 - 0.5

2.0

3

No. 2 ring

0.3- 0.5

1.5

4

Oil ring

0.3- 0.45

1.0

Replace piston or piston ring

Replace piston ring or cylinder liner

Standard size

Tolerance

40

0 -0.005

40

+0.015 0

Replace piston

Standard clearance

Clearance limit

0 - 0.020

0.05

Replace piston or piston pin

Engine No. 10001 to 49999

1160 ± 15 (g)

Engine No. 50001 and up

1141 ± 15 (g)

Replace piston pin

Replace piston

Onan Komatsu 0665T Engine Maintenance Standards

PISTON, PISTON RING, PISTON PIN

CHECK METHOD OF PISTON GROOVE

* *

This method apply only top and second ring of turbocharged engines.

Perform the inspection of the top ring groove and the second ring groove using a new piston ring and a feeler gauge.

1. Completely remove the carbon in the piston ring groove and after cleaning insert a new ring into the ring groove.

2. After pressing the ring with your fingers until ring reaches bottom of piston groove as shown in the figure at right, check to see whether or not a 0.15 mm gauge fits in.

3. If the gauge easily fits in without applying any strength, the wear of the piston ring groove has exceeded the allowance and so the piston must be changed.

4. If the gauge does not fit in without applying any strength, the piston can be reused for this ring groove.

Piston

0.15 mm thickness gauge

Unit: mm No.

1

Check item

0.0. of piston

Thickness of piston ring 2

3

Width of piston ring groove

4 Clearance between piston ring and piston ring groove

Piston ring gap

O.D. of piston pin

5

I.D. piston pin hole Clearance between piston pin and piston

-

Weight of piston

Remedy

Criteria Standard size

Tolerance

Repair limit

105

-0.160 -0.200

104.80

Standard size

Tolerance

No.

Inspection point

2

No. 1 ring

3

3

No. 2 ring

2.5

4

Oil ring

5

2

No. 1 ring

3

No. 2 ring

4

Oil ring

No.

Inspection point

2

No. 1 ring

3

No. 2 ring

4

Oil ring

2

--0.01 -0.03

Measure feeler gauge (Refer to figure)

Standard clearance

0.03- 0.07

0.15

No. 1 ring

0.3 - 0.5

2.0

3

No. 2 ring

0.3-0.45

1.5

4

Oil ring

0.3 - 0.45

1.0

Standard size

0 -0.005

40

+0.015 0

Engine No. 10001 to 49999 Engine No. 50001 and up

Replace piston or piston ring

Replace piston ring or cylinder liner

Tolerance

40

0 - 0.020

Replace piston

Clearance I imit

Measure groove wear gauge

Standard clearance

Replace piston ring

+0.04 +0.02

5

I

Replace piston

I

I

Clearance limit 0.05 1,200 ± 15 (g) 1,191 ± 15 (g)

Replace piston pin

Replace piston Replace piston or piston pin Replace piston

Onan Komatsu 0665T Engine Maintenance Standards

CONNECTING ROD 4

5

2 6 Unit: mm No.

C heck item

3

I

Standard size

I.D. of bushing at small end of connecting rod

2

Remedy

Criteria

40

Tolerance

Clearance between bushing and piston pin at small end of connecting rod

Standard clearance

Clearance limit

0.025 - 0.050

0.10

I.D. of bushing securing hole at smal I end of connecting rod

Standard size

I.D. of bearing mounting hole at big end of connecting rod

.

Replace bushing or piston pin

Tolerance Replace connecting rod .

+0.035

43

I.D of bearing at big end of connecting rod (Crank pin journal)

Replace bushing

+0.040 +0.025

+0.010

Standard size

Tolerance

Repair limit

66

+0.035

66.15

70

+0.025 0

70.04

+0.010

Replace bearing

Measure after tightening the connecting rod cap by prescribed torque.

Bend

5

Bend and twist of connecting rod

0� I .

Twist�

� J_j/

Tightening sequence Tightening torque of connecting rod cap securing bolts 6

-

(Coat the bo It threads and nut seats with engine oil.)

Connecting rod weight

1st 2nd

Bend (Repair limit):

0.08

Twist (Repair limit):

0.30

Replace connecting rod

14F021

Target value (kq.m)

6 11

Range (kg.m)

5-7 10-12

Loosen

0

0

3rd

6

5-7

4th

11.2

10.6-11.7

Standard size: 2087 ± 70 (g)

T ighten

Replace connecting rod

Onan Komatsu 0665T Engine Maintenance Standards

FLYWHEEL AND FLYWHEEL HOUSING

lfr.Sl�m--1

�--2 .W-tt----4

6 Unit: mm No.

Check item

Criteria

1

Face runout of the flywheel housing

Repair limit: 0.35

Remedy

Correct by reassembly.

2

Radial runout of the flywheel housing

Repair limit: 0.30

Range (kg.m)

Target value (kg.m) 3

4

Tightening torque of the flywheel housing mounting bolts

11

Face runout of the flywheel

9.5 -12.5

Tighten

Repair limit: 0.20 Correct by assembly

5

Radial runout of the flywheel

Repair limit: 0.15

Tightening sequence Tightening torque of the flywheel mounting bolts (Coat the bolt threads with engine oil)

� �

1st

tr ➔'"' �

I 4F024

Target value (kg.m)

Range (kg.m)

9

6-12

18

16-20

Tighten

Onan Komatsu 0665T Engine Maintenance Standards

LUBRICATING SYSTEM

OIL PUMP

Engine No. 10001 - 49999

4

5

3

6

Unit: mm No.

Check item

Criteria Tolerance

Axial clearance of rotor

Standard size

33 2

Radial clearance of rotor

78

Clearance between shaft and bushing

22

4

Clearance between oil pump and block

33

5

Interference between pump gear and shaft

3

6

Backlash between oil pump gear and pump drive gear

Thickness of rotor

Depth of rotor room

Remedy

Standard clearance

Clearance limit

0 -0.020

+0.090 +0.050

0.0500.110

0.15

O.D. of rotor

I.D. of rotor room

Standard clearance

Clearance limit

0.1100.135

0.25

Standard clearance

Clearance limit

-0.10 -0.13

+o.055 +o.010

Shaft

Hole

0 -0.015

+0.060 +0.030

0.0300.075

0.10

-0.010 -0.035

+0.025 0

0.0100.060

0.10

Standard interference

Repair limit

O.D. of shaft

I.D. of gear

22 0 -0.015

-0.040 -0.060

0.0250.060

Standard clearance

Clearance I imit

0.120- 0.370

0.60

Replace

Replace bushing

Replace

Replace

0.02

Repair or replace

Onan Komatsu 0665T Engine Maintenance Standards

Engine No. 50001 and up 6 4 3

5 9 8

1 Unit: mm

No.

Standard size Axial clearance of pump gear 32

2

Radial clearance of pump gear

Standard size

51.4

Interference between pump drive gear and drive shaft

Remedy

Criteria

Check item

Standard size

Tolerance Thickness o gear

Depth of body

0 -0.025

+0.065 +0.040

Tolerance O.D.of gear 1.D. of body -0.15 -0.21

+0.06 0

Tolerance Shaft

Hole

Standard clearance (End play)

Clearance limit (End play)

0.03 - 0.09

0.10 Replace gear

Standard clearance

Clearance limit

0.03 - 0.10

0.13

Standard clearance

Clearance Iimit

-

Replace

18

+0.105 +0.090

+0.060 +0.045

Interference 0.030 - 0.060

4

Clearance between drive shaft and cover bushing

18

+0.105 +0.090

+0.175 +0.145

0.040 - 0.085

5

Interference between pump gear and drive shaft

18

+0.105 +0.090

+0.065 +0.045

Interference 0.025 - 0.060

6

Clearance between drive shaft and body bushing

18

-0.005 -0.025

+0.060 +0.035

0.040 - 0.085

7

Clearance between driven shaft and body

18

+0.080 +0.065

+0.130 +0.100

0.020 - 0.065

8

Clearance between driven shaft and body bushing

18

+0.080 +0.065

+0.145 +0.120

0.040 - 0.080

9

Interference between driven shaft and cover

18

+0.080 +0.065

+0.040 +0;020

Interference 0.025 - 0.060

Replace bushing

-

Replace

Replace bushing

-

Replace

Replace bushing

-

Replace

LUBRICATING SYSTEM

Onan Komatsu 0665T Engine Maintenance Standards

ENGINE OIL PRESSURE REGULATOR AND SAFETY VALVE Engine No. 10001 - 49999

3

2

·-

�-= ===--=-=

-·

l

l

·- ·-

=::-....::=

:-..

l

t--- 6

I 5

4

I

14F027

Unit: mm No.

Check item

Criteria

Remedy

Tolerance Standard size 1

Clearance between valve a_nd valve body

Shaft

Hole

-0.020 -0.040

+0.050 +0.020

Replace 20

68.7

I

4

Safety valve actuating pressure

Replace

Installed length

Standard load (kg)

Repair limit (kg)

6 0.4

17.1

16.5

Standard torque (kg.ml

Tightening torque of regulator valve body

Regulator valve cracking pressure

6

Installed load

Regulator valve spring

Tightening torque of regulator valve plug

0.040- 0.090

Standard size

Free length

2

Standard clearance

Allowance (kg.ml

Tightening

10

8- 12

10

8- 12

Tightening

2

Adjust

Parts number 6136-51-4100

8.5 ± 0.25 kg/cm

2

2.0 ± 0.2 kg/cm

Replace cartridge

· LUBi:tlCATING SYSTEM

Onan Komatsu 0665T Engine Maintenance Standards

Engine No. 50001 and up

3

2

Unit: mm No.

Check item

Tolerance

Standard size 1

Remedy

Criteria

Clearance between valve and valve body 16

Shaft

Hole

-0.040 -0.060

+0.045 0

Standard clearance Replace 0.040 - 0.105

• Free length Standard size: 49.1 2

3

Regulator valve spring

Regulator valve actuating pressure

• Installed load

Replace

Installed length

Standard load ( kg)

34.8

10.8

Standard: 6.5 ± 0.5 kg/cm 2

Repair limit (kg) 9.8 Repair or replace spring

Onan Komatsu 0665T Engine Maintenance Standards

COOLING SYSTEM

COOLING SYSTEM

0665T WATER PUMP, 0665T THERMOSTAT

Unit: mm No.

Check item

Interference between impeller bore and shaft

Criteria Standard size

15.9 2

Clearance between impeller and body

3

Abrasion of seal ring in water seal

4

Bend of shaft

5

Thermostat full-opening lift Thermostat open and shut

Remedy

Tolerance Shaft

Hole

+0.020 +0.005

-0.020 -0.050

Standard clearance: 0.18

Standard interference

Replace impeller

0.025 - 0.070

~ 1.47 (include end play)

Dimension A: Repair limite: 0

Replace

-'- ,.co,,' Repair limit: 0.1 mm (Specified as face runout at 40 mm radius of pulley) 10 min.

°

Dip in hot water bath at 90 C for 4 or 5 minutes. Then, inspect it.

° First, dip in 90 C hot water bath for 4 or 5 minutes, (The valve will open ° fully). Then dip in 71 C hot water for 4 or 5 minutes. The valve should close fully.

Replace

Onan Komatsu 0665T Engine Maintenance Standards

INTAKE AND EXHAUST SYSTEM

INTAKE AND EXHAUST SYSTEM

TURBOCHARGER 2

3

C

D

Unit: mm No.

Tolerance

Radial play of rotor

2

Axial play of rotor

3

Tightening torque of blower housing

4

Tightening torque of turbine housing bolt

5

Thickness of thrust bearing

Remedy

Criteria

Check item

Repair limit

0.075 -0.150

0.18

0.025 - 0.075

0.10

Repair or replace

Range (kgm)

Target (kgm)

1.3

1.15-1.5

2.0

1.8 - 2.2

Standard size

Tolerance

4.36

4.35

Tightening

• O.D. Position 6

O.D. or bending of wheel shaft

Standard size

A

portion

10.155

10.13

B

portion

17.340

17.29

• Bending

I.D. of back plate

Repair limit

I .D. of center housing

12.73

12.70 Position

8

Replace

Repair limit: 0.010 (T.1-R) Standard size

7

Repair limit

Standard size

Repair limit

C

portion

15.80

15.81

D

portion

18.03

18.08

Introduction ABOUT THIS MANUAL This manual provides general information for operating and maintaining your Onan generator set. Study this manual carefully and observe all warnings and cautions.

Using the generator set properly and following a regular maintenance schedule will result in longer unit life, better performance, and safer operation.

HOW TO OBTAIN SERVICE When the generator set requires servicing, contact an Onan Distributor for assistance. Onan factory trained Parts and Service representatives are ready to handle all your service needs.

When contacting an Onan Distributor, always supply the complete Model number and Serial number as shown on the Onan nameplate. The Onan nameplate is located on the side of the generator control box.

Onan Nameplate

WARNING

'

INCORRECT SERVICE OR REPLACEMENT OF PARTS MIGHT RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE. SERVICE PERSONEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANICAL SERVICE.

2

Specifications DVC GENERATOR DETAILS Type .................................................... Onan, Revolving Field, 4-Pole, Brushless Rating 60 Hertz Continuous Standby ........................................ 100 kW (12 5 kVA at 0.8 PF) 50 Hertz Continuous Standby ......................................... 8 3 kW (104 kVA at 0.8 PF) AC Voltage Regulation, 0 to 100% Load ..................................................... ±3%

ENGINE DETAILS Engine ............................................................................. Onan 066 5T Engine Speed (r/min) 50 Hertz Operation ....................................................................... 1500 60 Hertz Operation ....................................................................... 1 800 Fuel .......................................................................... ASTM No. 2 Diesel Fuel Inlet Size ...................................................... For 3/ 8 in. (10 mm) 1.0. Hose Fuel Return Outlet ............................................... For 3/16 in. (4.76 mm) 1.0. Hose Fuel Pump Maximum Lift ............................................................. 3.5 ft (1 m) Exhaust Outlet ..................................................................... 3-in. Flange Starting System Voltage ...................................................................... 24 Battery Requirements BCI Group Size ............................................................................ 4D Cold Cranking Amps@0 ° F (-1 8 ° C) ....................................................... 700 Battery Voltage ............................................................................ 12 Quantity Required .......................................................................... 2 Cooling System (Engine and Radiator) ........................................... 6 gallons (23 L) Engine Oil Capacity (Filter, Lines, and Crankcase) ................................... 6.3 gal (24 L)

Onan Komatsu 0665T Diesel Generator Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

3

DVD GENERATOR DETAILS Type .................................................... Onan, Revolving Field, 4-Pole, Brushless Rating 60 Hertz Continuous Standby ........................................ 125 kW (156 kVA at 0.8 PF) 50 Hertz Continuous Standby ........................................ 100 kW (125 kVA at 0.8 PF) AC Voltage Regulation, Oto 1 0 0% Load ..................................................... ±3%

ENGINE DETAILS Engine ............................................................................. Onan 06 71T Engine Speed (r/min) 50 Hertz Operation ....................................................................... 1500 60 Hertz Operation ....................................................................... 1800 Fuel ..........................................................................ASTM No. 2 Diesel Fuel Inlet Size ...................................................... For 3/ 8 in. (10 mm) 1.0. Hose Fuel Return Outlet ............................................... For 3/16 in. ( 4.76 mm) 1.0. Hose Fuel Pump Maximum Lift .............................................................. 3.5 ft (1m) Exhaust Outlet ...................................................................... 3-in Flange Starting System Voltage ...................................................................... 24 Battery Requirements BCI Group Size ............................................................................ 4 0 Cold Cranking Amps@ 0 ° F (-18 ° C) ....................................................... 70 0 Battery Voltage ............................................................................ 12 Quantity Required .......................................................................... 2 Cooling System (Engine and Radiator) ............................................ 6 gallons ( 23 L) Engine Oil Capacity (Filter, Lines, and Crankcase) ...................................6.3 gal. ( 24 L)

DVE GENERATOR DETAILS Type .................................................... Onan, Revolving Field, 4-Pole, Brushless Rating 60 Hertz Continuous Standby ........................................ 15 0 kW (18 8 kVA at 0.8 PF) 50 Hertz Continuous Standby ........................................ 1 20 kW (150 kVA at 0.8 PF) AC Voltage Regulation, 0 to 100% Load ..................................................... ±3%

ENGINE DETAILS Engine ............................................................................Onan 06 71TA Engine Speed (r/min) 50 Hertz Operation ....................................................................... 1500 60 Hertz Operation ....................................................................... 1800 Fuel .......................................................................... ASTM No. 2 Diesel Fuel Inlet Size ...................................................... For 3/ 8 in. (10 mm) I.D. Hose Fuel Return Outlet ............................................... For 3/16 in. ( 4.76 mm) 1.0. Hose Fuel Pump Maximum Lift .............................................................. 3.5 ft (1m) Exhaust Outlet ...................................................................... 3-in.Flange Starting System Voltage ...................................................................... 24 Battery Requirements BCI Group Size ........................................................................... 4D Cold Cranking Amps@ 0 ° F (-18 ° C) ....................................................... /00 Battery Voltage ............................................................................ 12 Quantity Required .......................................................................... 2 Cooling System (Engine and Radiator) ........................................ ... 6 galions (23 L) Engine Oil Capacity (Filter, Lines, and Crankcase) ................................... 6.3 gal (24 L)

4

Operation l

GENERAL

Spllled fuel might Ignite and cause WARNING ------•- serious personal Injury or death.

Never fill the fuel tank when the engine is running.

This section covers starting and operating the gener­ ator set. It is recommended that the operator read through this entire section before attempting to start the set. It is essential that the operator be completely familiar with the set to insure safe operation.

CONTROL PANEL The following describes the function and operation of the standard generator set control. All instruments and control switches are located on the face of the control panel as illustrated in Figure 1. The control panel is separated into a DC panel for monitoring the engine and an AC panel for monitoring the generator.

PRESTART CHECKS Before starting, be sure the following checks have been made and the unit is ready for operation. Refer to the MAINTENANCE section for the proper procedures.

DC Panel Panel Lamp: Illuminates control panel.

Lubrication

Check the engine oil level. Keep the oil level near as possible to the dipstick high mark without overfilling.

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

Coolant

The coolant level should be about two inches below the radiator cap opening. Do not check while the coolant is hot.

Water Temperature Gauge: Indicates temperature of circulating coolant in engine (wired to a sensor unit located on the engine).

[ WARNING ' Contact with hot coolant might result in serious burns. Do not bleed hot, pressurized coolant from a closed cooling system.

Battery Charge Rate DC Ammeter: Indicates the bat­ tery charging current.

Run-Stop-Remote Switch: Starts and stops the unit locally, or from a remote location wired to the control engine monitor board.

Fuel Make sure the fuel tanks have sufficient fuel. See the MAINTENANCE section for recommended fuel.

Fault Lamps: Indicate fault in engine operation. The Run and Fault lamps are standard, other lamps are -control options. See description under "Indicator Lamps."

WARNING '

EXHAUST GAS IS DEADLY! Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include: • • • •

Dizziness Nausea Headache Weakness and Sleepiness

• • • •

Throbbing in Temples Muscular Twitching Vomiting Inability to Think Coherently

IF YOU OR ANYONE ELSE EXPERIENCE ANY OF THESE SYMPTOMS, GET OUT INTO THE FRESH AIR IMMEDIATELY. If symptoms persist, seek medical atten­ tion. Shut down the unit and do not operate until it has been inspected and repaired.

Protection against carbon monoxide inhalation includes proper installation and regular, frequent visual and audible inspections of the complete exhaust system.

5

1-P/EM

Voltage Adjust (Optional): Rheostat providing ap­ proximately plus or minus five percent adjustment of the rated output voltage.

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

Field Breaker: Provides generator exciter and regula­ tor protection from overheating in the event of certain failure modes of generator, exciter and voltage regu­ lator.

Reset, Lamp Test, Panel Lamp Switch: Resets the fault circuit only when the Run-Stop-Remote switch is in the Stop (Reset) position. Tests fault lamps and turns on the control panel lamp.

Phase Selector Switch (Optional): Selects phases of generator output to be measured by AC voltmeter and AC ammeter.

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

Indicator Lamps

AC Ammeter (Optional): Indicates AC generator line current.

The standard control panel has two monitor system indicator lamps.

Frequency Meter (Optional): Indicates generator output frequency in hertz. It can be used to check engine speed. (Each hertz equals 30 r/min).

• RUN (green) • FAULT (red)

VOLTAGE .AQJUSTfNG RHEOSTAT

The green Run lamp comes on as soon as both prim­ ary and secondary starter circuits are opened after unit starting. The red lamp indicates an emergency shutdown of the generator set.

UPPERAND LOWER SCALE INDICATOR LAMPS

RUN-STOP (RESET) REMOTE SWITCH

PANEL LAMP

/

FAULT LAMPS

DUAL RANGE AC VOLTMETER--..--....--

COOLANT TEMPERATURE GAUGE

AC AMMETER --�!+--..L_

DC AMMETER FREQUENCY METER

RUNNING TIME METER

FIELD BREAKER

(I)

l________ )l____ J y y DC PANEL

AC PANEL

M-1590

FIGURE 1.

OPTIONALCONTROLPANEL(12FAULTLAMPS)

6

CONTROL PANEL INTERIOR

The optional control panel has a twelve-lamp moni­ toring system. The following describes each lamp function.

Generator AC Voltage Regulator

The solid-state regulator (VRAS-2) controls AC out­ put voltage from the generator at a predetermi:ied level regardless of load. Voltage reguiation is plus or minus three percent from no load to full load. Ran­ dom voltage variation is p!us or minus one percent for constant loads.

• RUN (green) lamp comes on when both starter circuits are opened after unit starting.

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

Engine Control Module

:: PRE H! ENG TEMP (yellow) indicates engine temperature is marginally high.

Electronic and relay components of the er.gine mor:i­ torlng circuit are on a circuit.board assembly. Sensor inputs (Figure 2) are connected by the wiring har:iess to plug connectors on the board. The cont:c: �oduie provides the following functions of unit protection.

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

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

• Overcrank- limits engine cranking to 75 seconds. If engine fails to start, the module lights a fault lamp and opens the cranking circuit. The cycle cranking option allows three 15-second cranking cycles with two 15-second rest periods on the 12-lamp control.

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

• OVERCRANK (red) indicates the starter has been locked out because of excessive cranking time.

• Overspeed - shuts down the engine immediately if overspeed occurs and lights a fault lamp. The sen­ sor switch is mounted in the end bell on the gener­ ator shaft. It is factory adjusted to shut down 60 hertz units at 2200 ± 100 r/min, 50 hertz units at 1900 ± 100 r/min.

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

• FAULT 2 (red) S ame features as Fault 1 (Normally set for timed shutdown).

• Low Oil Pressure - shuts down the engine imme­ diately if oil pressure drops below 14 psi (97 kPa) and lights a fault lamp. The fault is time delayed about 10 seconds foliowing starter disconnect and inhibited during cranking. The delay allows oi: pressure to rise to normal before the electronic control module monitors this system.

• LOW ENG TEMP (yellow) engine temperature is marginally low for starting. Indicates inoperative coolant heater.

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

A pre-low oil pressure sensor and lamp (used with optional 12-lamp system) provides an alarm that oil pressure is marginally low (20 psi/138 kPa or less).

The cause should be found and corrected as soon

• SWITCH OFF (flashing red) indicates generator set is not in automatic start operation mode.

as possible.

7

• High Engine Temperature - shuts down the engine immediately if coolant temperature rises above 227 ° F (108 ° C) and lights a fault lamp. The fault is time delayed about 10 seconds following starter disconnect and inhibited during cranking.

This delay allows coolant in a hot engine time to circulate and return the water jacket to normal before the electronic control module monitors this system.

� The high engine temperatu re � shu t down wlll shu t dow n engine I n an overheat condition only I f coolant level Is s ufficient ly high to physically contact shutdown swit ch. Loss of coolant w/11 allow engine to overheat without protectio n of shut­ down device. thereby causing severe damage to the engine. Therefore. maintain adequate engine coolant levels to ensure operatio nal Integrity of cooling s ystem and engine coolant o verheat shutdown protectio n.

A pre-high engine temperature sensor and lamp used with optional 12-lamp systems, provides an alarm that engine temperature is marginally high (216 ° F/102 ° C). The cause should be found and corrected as soon as possible.

___ _1�,,n::-::-

=9 ==-�

'

• Low Coolant Level Shutdown (If Used): A coolant level actuated switch located in the radiator top tank providing engine shutdown if coolant level falls too low. It turns on the high engine tempera­ ture fault lamp on the control.

HIGH COOLANT TEMPERATURE

'

-- �

COOLANT TEMPERATURE SENDER

PRE-HIGH COOLANT TEMPERATURE *HIGH COOLANT TEMPERATURE

I

DETAIL "A" (DVD, DVE)

*COOLANT TEMPERATURE SENDER

LOW ENGINE TEMPERATURE

n ; i oo

�--

FIGURE 2.

,,-; H�, :LJ· _rjCC--

SENSOR LOCATIONS

8

--

�

\J-\fr; ___J

�-�Tl

lJ

:

'

'

.': 1LJ

,

�--�MODEL DVC SEE DETAIL "A"FOR MODELS DVD & DVE

STARTING PROCEDURE The following sections cover the three systems used to start the generator set.

To Stop

Move the Run-Stop-Remote switch or the remote starting switch to the STOP position.

Starting at Control Panel

OPERATING RECOMMENDATIONS Some of the following sections require that a load be connected to the generator set. This is usually done using a load transfer switch. Refer to the transfer switch operator's manual for operation information.

Move the Run-Stop-Remote switch on the DC panel (Figure 1) to the RUN position. This will activate the engine control system and the starting system. The starter will begin cranking and after a few seconds the engine should start. The starter will disconnect when the engine reaches a speed of 450 to 570 r/min. The starter will also disconnect if the engine does not run after being cranked for a specified period of time.

No-Load Operation

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

Closing the remote switch initiates the starting sequence described in the previous section.

Hold periods of no-load operation to a minimum and avoid if possible. No-load operation allows combus­ tion chamber temperatures to drop so low that the fuel does not burn completely. This results in carbon dep­ osits which can clog injectors and cause piston rings and valves to stick. If it is necessary to run the engine f o r l o n g p e r i o d s a t n o l o a d, c o n n e c t a "dummy" electrical load to the generator.

Automatic Remote Starting

Exercise Period

Starting From Remote Location

Generator sets on continuous standby must be able to go from a cold start to being fully operational in a matter of seconds. This can impose a severe burden on engine parts.

Place the Run-Stop-Remote switch on the generator set DC panel in the REMOTE position if an automatic transfer switch is used. This allows the transfer switch to start the generator set if a power outage occurs.

To avoid excessive engine wear, exercise the genera­ tor set at least once a week for minimum of 30 min­ utes. Run the set with a load applied to allow the engine to reach normal operating temperature. Exer­ cising will keep the engine parts lubricated, maintain fuel prime, and prevent electrical relay contacts from oxidizing to insure reliable starts. Top off the fuel tank after each exercise period.

Start-Up Checks

Observe the oil pressure gauge after the engine is started. A normal oil pressure reading (at operating temperature) is between 40 and 80 psi (275 and 550 kPa). The following gauges should also be checked for normal readings: DC Ammeter - Normal charging rate is 1 to 15 amperes depending on battery state of charge.

AC Voltmeter - Generator output voltage should be stable and not vary more than ±1% of the rated value while under load.

Onan automatic transfer switches have as an option an exerciser that can be preset to provide regular exercise periods. Typically, the exerciser can be set for time of start, length of run, and day of week.

Frequency Meter - Generator frequency should be stable.

High/Low Operating Temperature The following recommendations app!y when operat­ ing the generator set in high (above 95 ° F/35 ° C) or low (below 50° F/10 ° C) ambient temperatures.

Water Temperature - Run the generator set for about 10 minutes and then check the water temperature gauge. The engine should stabilize between 175 and 212 ° F (80to 100° C).

1. Use the correct viscosity oil for the most extreme expected ambient temperature con(.itions. If it is necessary to change oil, drain the cd only when the engine is warm.

2. Use only fresh diesel fuel and keep the fuel tank completely filled to prevent condensation of moisture. Use ASTM #: fuel at temperatures below 14 ° F (-10 ° C).

3. Keep the batteries fully charged and keep all bat­ tery connections clean and free of corrosion.

STOPPING

Before Stopping

Run the generator set at no load for three to five minutes before stopping. This allows the lubricating oil and engine coolant to carry heat away from the combustion chamber and bearings.

9

The out-of-service time interval should not be extended beyond 30 days. Once-a-month operation restores oil films on internal engine surfaces. The inherent lubricating qualities of No. 2 diesel fuel should protect the cylinders of a diesel engine for 30 days when unit is not in service.

4. For low temperatures, use a water jacket heater if a separate source of power is available. The optional heater is available from Onan and will assure reliable starting under adverse weather conditions. Be sure the voltage of the separate power source is correct for the heater element rating. Various voltage combinations are available.

TROUBLESHOOTING

See low temperature fuel recommendation in the Maintenance Section.

The generator set has a number of sensors that con­ tinuously monitor the engine for abnormal condi­ tions. The engine monitor will turn on a fault lamp, activate an external alarm and stop the engine depending on the condition. If the generator set shuts down, the operator might restart the set after making some adjustments or corrections.

Power Rating Factors

The generator set power rating applies to sets used in continuous standby applications. The set will operate at the stated rating for the duration of normal utility power interruptions. The rating was established for a standard radiator cooled set running on #2 diesel fuel and operating at an altitude of 300 feet (91 m) with an ambient temperature of 77 ° F (25 ° C). For a rating relative to other applications, altitudes, cooling sys­ tems, ambient temperatures, or fuels, contact an auth­ orized Onan Distributor.

The following troubleshooting charts list symptoms and corrective action for the three fault systems. See Table 1 for the fault lamp options and included features.

If the external alarm is activated, check the control panel to determine which fault lamp is lit. The proce­ dures for locating a problem and making corrections are covered in Tables 2 through 3. If a major problem is indicated, contact your Onan Distributor for service.

OUT-OF-SERVICE PROTECTION Onan recommends the exercise of generator sets at weekly intervals. Onan transfer switches can perform this function automatically and also keep the starting battery charged. If the generator set will be out-of­ service longer than this, seethe following recommendation.

TABLE 1. FAULT LAMP OPTIONS SYSTEM

Standard Fault Lamp and Run Lamp 12-Lamp (Includes RUN lamp)

FAULT

Overcrank Overspeed Low Oil Pressure High Engine Temperature Overcrank Overspeed Low Oil Pressure High Engine Temperature Pre Low Oil Pressure Pre High Engine Temperature Low Engine Temperature Low Fuel Switch Off (In Stop Mode) Two Customer Selected Faults

FAULT LAMP x1 x1 x1 x1

STOP EXTERNAL ALARM ENGINE X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X

X X

*x *x

X X X

X

X

X

"If factory programmed for shutdown x, Single fault lamp for four faults.

10

X

*x *x

X

Resetting the Control The external alarm and fault lamp can be deactivated by placing the Run-Stop-Remote switch in the Stop position and pressing the adjacent Reset button.

Locate the problem and correct before restarting the generator set.

High voltages are the present within the control box when the generator set is running. Do not open the control box unless the generator set is disabled. [ WARNING

I

Accidental starting of the generator set might cause severe personal injury of death. Place the control switch in Stop posi­ tion and disconnect the battery cable before inspect­ ing set.

TABLE 2.

TROUBLESHOOTING ENGINE SHUTDOWN SYSTEM Controls with only one fault lamp SYMPTOM

1. Engine stops cranking and fault lamp lights, after cranking approximately 75 seconds.

CORRECTIVE ACTION

1. Check for empty fuel tank, empty fuel filters, system leaks, or plugged fuel filters and fuel supply lines. Correct as required.

Check for dirty or plugged air filters and replace if necessary (see MAINTENANCE section).

2. Fault lamp lights immediately after engine starts and unit shuts down.

2. Indicates possible overspeed condition. Contact an Onan Distributor.

3. Fault lamp lights and engine shuts down after running for a period.

3. Check oil level and replenish if necessary.

Check coolant level on radiator and heat exchanger sets and replenish if necessary.

Check for slipping drive belts or for obstructions to the airflow.

Check for empty fuel tank, fuel system leaks, or plugged filters.

Contact an Onan Distributor if none of the above.

4. Fault lamp lights, no fault exists.

4. Engine monitor or sensor malfunction.

Contact an Onan Distributor.

11

TABLE 3.

TROUBLESHOOTING ENGINE SHUTDOWN SYSTEM Controls with twelve fauit lamps CORRECTIVE ACTION

SYMPTOM 1. Overcrank fault lamp lights and

1. Check for empty fuel tank, empty

2. Engine runs and then shuts down.

The low oil pressure fault lamp is on.

2. Check fuel supply and for dirty fuel filters. Replace if necessary. Check oil level and replenish if needed.

See MAINTENANCE section. Check for dirty or plugged air filters and replace if necessary (see MAINTENANCE section).

3. Low oil pressure shutdown; or

3. Check oil level and replenish if

4. High engine temperature shutdown; or

4. Check coolant level on radiator and

engine stops cranking after about 75 seconds.

.

pre low oil pressure shutdown if so programmed.

pre high engine temperature shutdown if so programmed.

fuel filters, system leaks, or plugged fuel filters and fuel supply lines. Correct as required.

necessary. Contact an Onan Distributor if oil level is correct. Also see Symptom 2.

heat exchanger sets a;id replenish if necessary.

Check for slipping drive belts or for obstructions to the airflow.

Contact an Onan Distributor if none of the above.

5. Overspeed shutdown.

5. Contact an Onan Distributor.

6. Anyone of the red fault lamps (or

6. Engine monitor malfunction.

7. Run lamp is not on when generator set is operating.

7. Indicates that a starter disconnect function is not working.

Contact an Onan Distributor.

yellow pre-fault lamps if programmed for shutdown) light, but no shutdown occurs.

Contact an Onan Distributor.

continued-

12

I

TABLE 3 (continued)

SYMPTOM 8. Low engine temperature fault circuit (yellow lamp) is energized.

9. Low fuel fault circuit (yellow

lamp) is energized.

10. An undedicated (red) fault lamp is energized and may or may not shut down the generator set.

CORRECTIVE ACTION 8. Check power source supplying the coolant heater. Problem might be a power outage or power disconnect (blown fuses). If coolant heater, sensor or engine monitor is suspected, contact an Onan Distributor.

9. Check fuel tank and replenish fuel as

needed. If fuel in tank is adequate/ full, contact an Onan Distributor.

10. Both fault functions are normally factory set for shutdown and Fault 1 is time delayed after start disconnect while Fault 2 is immediate. Both fault functions may be factory set optionally for non-shutdown and time delayed after start disconnect or immediate operation.

Troubleshooting should be directed to the selected sensor application. If an engine monitor malfunction or sensor is suspected, contact an Onan Distributor.

13

Maintenance Establish and adhere to a definite schedule for main­ tenance and service based on the application and severity of the environment. Table 4 covers the recommended service intervals for a generator set on standby service. If the set will be subjected to extreme operation conditions, the service intervals should be reduced accordingly. Some of the factors that can affect the maintenance schedule are the following: • • • • • •

Consult with an authorized Onan Distributor if the generator set will be subjected to any extreme operat­ ing conditions and determine a suitable schedule of maintenance. Use the running time meter to keep an accurate log of all service performed for warranty sup­ port. Perform all service at the time period indicated or after the number of operating hours indicated, whi­ chever comes first. Use the table to determine the maintenance required and then refer to the sections that follow for the correct service procedures.

Use for continuous duty (prime power) Extremes in ambient temperature Exposure to elements Exposure to salt water Exposure to windblown dust or sand Fuel sulphur content

TABLE 4. OPERATOR MAINTENANCE SCHEDULE MAINTENANCE SCHEDULE MAINTENANCE ITEMS

10 Hrs.

Inspect generator set Check oil level

x1

Check coolant level Check air cleaner (clean if necessary)

X

50 Hrs.

250 Hrs. 500 Hrs. 1000 Hrs. 2000 Hrs.

X

X

Check batteries Change engine crankcase oil Change oil filter Check alternator/fan belts Drain exhaust condensate trap Drain fuel tank water/sediment Change fuel filter element Check radiator, coolant hoses Clean cooling system & htr./replace coolant Check turbocharger Clean gen. assy./check generator bearing Change air cleaner element

X

x2,s x2 x3 X

x4 X

x3 X X X

x1

Clean crankcase breather element Check vibration damper

X X

Check valve clearances

xs

Check water pump Check for oil, fuel, cooling, and exhaust leaks. Check exhaust system audibly and visually with generator set running. Repair any leaks immediately.

2 - Or every 12 months, whichever occurs first. Perform more often for dusty conditions.

3 - Or every 3 months, whichever occurs first.

4 - Or every 12 months. Drain at least one cup of fuel to remove water and sediment. s - Initial adjustment at 250 hours.

6 - Perform more often for high sulphur content fuel. See text.

7 - Or sooner if service indicator shows restriction.

1

X X

-

14

SET INSPECTION

Fault Lamps: With the generator set stopped (Run­ Stop-Remote switch in Stop position), actuate the Lamp Test switch. Verify that all indicator lamps are on.

During operation, be alert for mechanical problems that could create unsafe or hazardous conditions.

The following sections cover several areas that should be frequently inspected to insure continued safe operation.

DC Electrical System

Check the terminals on the battery for clean and tight connections. Loose or corroded connections create resistance which can hinder starting. Clean and reconnect the battery cables if loose. Always connect the negative battery cable last to reduce the possibil­ ity of arcing.

Exhaust System

With the generator· set operating, inspect the entire exhaust system visually and audibly including the exhaust manifold, muffler, and exhaust pipe. Check for leaks at al I connections, welds, gaskets, and joints and also make sure that exhaust pipes are not heating surrounding areas excessively. If any leaks are detected, shut down generator set and have them corrected immediately.

[

ARNING l Ignition of explosive battery gases [._W____ _._ might cause severe personal injury.

l

Do not smoke while servicing batteries.

Inhalation of exhaust gases might WARNING .______._ result In serious personal Injury or death. Be sure deadly exhaust gas Is piped outside and away from windows, doors or other Inlets to building.

Mechanical

Follow warning below before proceeding. With the generator set stopped, check for loose belts and fit­ tings, leaking gaskets and hoses, or any signs of mechanical damage. If any problems are found, have them corrected immediately. With the set running, listen for any unusual noises that may indicate mechanical problems and check the oil pressure fre­ quently. Investigate anything that indicates possible mechanical problems.

Fuel System

With the generator set operating, inspect the fuel supply lines, return lines, filters, and fittings for leaks.

Check any flexible sections for cuts, cracks and abra­ sions and make sure they are not rubbing against anything that could cause breakage. If any leaks are detected, have them corrected immediately.

[

\

WARNING ' Accidental starting of the generator .______._ set might cause severe personal injury or death. Place the control switch in Stop posi­ tion and disconnect the battery cable before inspect­ ing set.

l

Ignition of fuel might cause serious WARNING .______._ personal injury or death by fire or explosion. Do not permit any flame, cigarette, or other igniter near the fuel system.

AC Electrical System

Check the following meters while the generator set is operating.

LUBRICATION SYSTEM The lubrication system must have oil of the recom­ mended classification and viscosity. Refer to the SPECIF/CATIONS section for the lubricating oil capacity.

Frequency Meter (if equipped): The generator fre­ quency should be stable and the reading should be the same as the nameplate rating (50 or 60 Hertz).

AC Voltmeter (If equipped): Turn the phase selector switch to each line-to-line phase selection shown on the volts scale (L1-L2 on single phase sets; L 1-L2, :..2-L3, and L3-L 1 on three phase sets). Read the AC voltmeter using the upper or lower scale as indicated b�' the scale indicator light. At no load, the line-to-line voltage(s) should be the same as the set nameplate rating.

Oil API Classification

The lubricating oil recommended in Table 5 satisfies the engine needs for satisfactory operation under most conditions. A publication entitled "Lubricating Oil Data Book" is available from EMA '.Engine Manu­ facturers Association) that list comm,"')rcially avai!a­ ble oils by brand name and the corresponding APi Classications. Once an oi! is selected, do not mix it with oils of another classification or add any oil additives.

AC Ammeter (if equipped): Turn the phase selector switch to each phase selection shown on the amps scale (L 1 and L2 on single phase sets; L 1, L2, and L3 on three phase sets). Read the ammeter using the upper or lower scale as indicated by the scale indica­ tor light. At no load, the current readings should be zero. With a load applied, each line current should be about the same.

Oil Viscosity

The viscosity of an oil is a measure of its resistance to flow at certain specified temperatures. The viscosity grades shown in Table 5 are satisfactory for most conditions.

15

TABLE 5. PROPER SELECTION OF FUEL AND LUBRICANTS KIND OF FLUID

AMBIENT TEMPERATURE -4 ° F -20 °

50 ° 10 °

14 ° -10 °

En6: ne ification CD

86 ° 30 °

104 ° 40 ° c

ftkt1l@f.• Ilkf@t@tt :SAE ooi@:@WMt't=.-.·... T?.:It}

1

UseAPI Class-

68 ° 20 °

t:nm '!t!f!f]}@}§Aedb.w!!'{![{(f]}f'

Diesel Fuel ♦ ASTM 0975 No. 1

I

Engine Oil Level

can blow out hot oil and cause serious burns while the engine is running. Do NOT check oil while the generator is operating.

Check the engine oil level during engine shutdown periods at the intervals specified in the Maintenance Table. Figure 3 shows the dipstick and oil fill loca­ tions. The dipstick is stamped with high and low marks to indicate the level of oil in the crankcase. For accurate readings, shut off the engine and wait five minutes before checking the oil level. This allows oil in the upper portion of the engine to drain back into the crankcase.

WARNING ' Crankcase pressure

Keep the oil level as near as possible to the high mark on the dipstick. Remove the oil fill cap and add oil of the same quality and brand when necessary.

� Do not operate the engine with the � oil level below the low mark or above the high mark. Overfllllng causes foaming or aeration of the oil while operation below the low mark causes loss of oil pressure.

Oil and Filter Change Use oil that meets the API classification and viscosity requirements as indicated in the previous section. If the engine is started when ambient temperature is lower than 32 ° F (0 ° C), use SAE 1 OW oil even though the ambient temperature might go to 50 ° F (10 ° C) during the day.

If API oil classification CD is not available, classifica­ tion CC can be used if the oil change interval is reduced to half.

DIPSTICK

FIGURE 3.

OIL FILL

LOCATION OF OIL FILL AND DIPSTICK

16

CRANKCASE BREATHER ASSEMBLY

When the fuel sulphur content is less than 0.5%, change engine oil as recommended in the Operat'?r Maintenance Schedule. If fuel sulphur content Is above0.5%, change oil more often as indicated in the following table:

Fuel Sulphur Cont.

Change Interval

0.5 to 1.0%

1/2 regular interval

Above 1.0%

1/4 regular interval

DYE

Oil and Filter Change Procedure: 1. Bring the engine up to operating temperature and then shut it off.

2. Open the drain valve and collect the engine oil in a pan. When the crankcase is drained, close the drain valve.

3. Unscrew the "spin-on" type oil filter and discard (see Figure 4).

4. Apply a light coat of oil to the gasket sealing surface of the new filter.

5. Install a new filter and tighten 2/3 turn by hand after the seal touches the sealing surface of the bracket. Do not overtighten.

6. Fill the crankcase with the amount of oil noted in the Specifications section.

7. Start the engine and check for oil leaks.

8. Shut off the engine, wait five minutes, and then check the oil level. Add oil if required.

AIR FILTER

OIL FILTER

FILTER 4.

FILTER LOCATION

Crankcase Breather Element

Service the crankcase breather during engine shut­ dowri periods at intervals specified in the Mainte­ nance Table. Perform more often for dusty conditions.

WARNING � Crankcase pressure ca� blow out I'-· _____ ..! hot oil and cause ser,ous burns

while the engine is running. Do NOT check oil while the generator set is operating.

To clean the crankcase breather element, remove top cover from the breather assembly shown in Figure 4.

Remove element, rinse in diesel fuel and reinstall. presents the hazard of fire and J_______._� Fuel explosion that might cause serious WARNING

personal injury or death. Do not permit any flame, cigarette, or other ignition source near the fuel.

17

FUEL SYSTEM

FUEL FILTER

Recommended Fuet The engine has been primarily designed to operate. on No. 2 diesel fuels since such fuels have a higher energy content and are generally lower in cost. Use No. 1 fuel for temperatures lower than 14° F (-10 ° C) or for all temperatures if altitudes are above 5000 feet (1500 m). The fuel should have a cetane rating of at least 40 and have less than 0.5 percent sulfur if possi­ ble. If sulfur content is higher, more frequent oil change intervals are necessary (described under"Oil and Filter Change").

FILTER BASE AIR BLEED PLUG

Fuel Handling Precautions Take appropriate precautions to prevent the entrance of dirt, water, or other contaminants into the fuel system. Filter or strain the fuel as the tank is filled.

! WARNING � Ignition of fuel might cause serious ._____..,._ personal injury or death by fire or explosion. Do not permit any flame, cigarette, or other igniter near the fuel system.

To avoid condensation problems, keep fuel supply tanks as full as possible by filling up each time the engine is used. In cold weather, warm fuel returning from the injectors heats the fuel in the supply tank. If the fuel level is low, the upper portion of the tank tends to form condensation. In warm weather, both the fuel and the tank will be warm during the daytime.

At night, cool air tends to lower the temperature of the tank more rapidly than the temperature of the fuel. If the fuel level is low, the upper portion of the tank will cool more rapidly and tend to form condensation.

Condensation (water) can cause clogging of fuel fil­ ters as well as freezing problems. In addition, water mixing with the sulphur in the fuel forms acid which can corrode and damage engine parts.

Fuel Filter/Air Bleed MANUAL TRANSFER PUMP

To replace the fuel filter, use this proce·dure.

1. Move the operation selector switch to Stop position.

2. Remove fuel filter (Figure 5) by turning it coun­ terclockwise with a filter tool.

3. Fill the new filter with clean fuel and install it after applying a light film of oil to the sealing surface.

4. Turn filter until sealing surface contacts filter base, then tighten it 2/3 turn by hand. Do not overtighten.

5. Loosen air bleed plug on top of filter base. Loosen knob of the manual transfer pump and move it up and down until air bubbles cease to come out of the bleed plug. Tighten bleed plug.

6. Loosen lock nut and air bleed plug on the injec­ tion pump. Bleed air by working the manual pump as in the previous procedure.

INJECTION PUMP

FIGURE 5.

18

AIR BLEED COMPONENTS

7. Tighten air bleed plug and lock nut. Push in and tighten knob of the manual transfer pump.

8. Start the engine and check filter sealing surface for any fuel leakage.

Coolant Heater

Check the operation of the coolant heater by verifying that hot coolant is being discharged from the outlet hose (see Figure 6). For efficient operation and maximum life, clean the coolant heater whenever the cooling system is drained for flushing.

COOLING SYSTEM The cooling system capacity of standard units with set mounted radiator is shown in the SPECIFICA­ TIONS section.

1. Remove AC power from coolant heater.

WARNING ' AC power presents the hazard - of serious personal Injury or death. Be sure to remove AC power before cleaning.

� The heater must not be operated

[

� while the cooling system is empty or damage to the heater will occur.

Coolant Requirements

2. Allow heater to cool before proceeding.

A satisfactory engine coolant inhibits corrosion and protects against freezing. A 50/50 percent solution of ethylene glycol anti-freeze and water is recom­ mended for normal operation and storage periods.

Choose only a reliable brand of anti-freeze that con­ tains a rust and corrosion inhibitor but does not con­ tain a stop-leak additive.

[

WARNING ' Contact with hot coolant might

.______._ result in serious burns. Do not

bleed hot, pressurized coolant from cooling system.

3. Drain the coolant into a container.

A. Open the radiator drain cock.

B. Open the coolant heater drain cock on bottom of heater if equipped. See Figure 6.

The water used for engine coolant should be clean, low in mineral content, and free of any corrosive chemicals such as chloride, sulphate, or acid. Use soft water whenever available. Well water often con­ tains lime and other minerals which eventually may clog the radiator core or reduce cooling efficiency.

JUNCTlm BOX

Filling the Cooling System (Radiator and Heat Exchanger Sets)

Remove the cooling system pressure cap and fill the system with a water/anti-freeze mixture. When the engine is first started, remove the pressure cap and monitor the coolant level. As trapped air is expelled from-the system, the coolant level will drop and addi­ tional coolant should be added. Replace the pressure cap when the coolant level is stable. [

a closed

INLET

WARNING ' Contact with hot coolant might

.______._ result In serious burns. Allow cool-

ing system to cool before releasing pressure.

All models have air bleed petcocks or plugs that can be opened to facilitate filling of the cooling system.

Modei differences are listed below. Close the petcock or replace plug when coolant starts flowing from it.

DVC: Petcock on the thermostat housing.

DVD: Petcock on top of the water pump, and a air bleed plug on thermostat housing.

DVE: Petcock on top of the water pump.

ELEMENT

FIGURE 6.

M-1589

COOLANT HEATER

4. Remove the head and valve assemt !y of heater.

5. Clean any scale deposits out of the :ank.

6. Remove heating element and scrape cff any scale deposits that have accumulated on the sheathing.

7. Reassemble the heater.

Coolant Level Check the coolant level during shutdown periods at the intervals specified in the Operator Maintenance Schedule. Remove the r.:;.diator cap after allowing the engine to cool and if necessary, add coolant until the level is up to the overflow pipe.

� When reassembling threaded � aluminum parts, be sure to use anti-seize compound.

8. Restore AC power to heater after system has been filled with coolant.

19

Flushing and Cleaning Cooling System 1. Add system cleaner or flush solution to the radia­ tor as instructed on the container. Also follow instructions for running the unit. Proceed to step 2 when instructed to stop the engine.

2. Move the control selector switch to Stop.

3. Remove AC power to the coolant heater if equipped. � Failure to disconnect AC power � from the heater before draining coolant will result in heater damage.

4. Wait for the engine to cool before draining the cooling system.

I

WARNING � Contact with hot coolant might

- result in serious burns. Use care when draining coolant into a container.

A. Remove the radiator cap and open the radia­ tor drain cock. See Figure 7.

B. Open the engine block drain cock located next to the oil filter base. (The block drain is removed when a coolant heater is installed.)

C. Open the coolant heater drain on bottom of heater if equipped. See Figure 6.

CYLINDER BLOCK DRAIN COCK

5. Flush cooling system if so instructed by cleaner or flush solution manufacturer. Do not add cold water or solution to a warm engine. � Adding cold solution to a warm � engine might result in engine damage.

6. Close all the drain cocks.

7. Fill the cooling system with a 50/50 percent solu­ tion of ethylene glycol and water with approved rust inhibitor.

8. Reconnect AC power to the coolant heater if applicable.

9. Move the control selector switch to Run position and operate engine for ten minutes to purge trapped air.

10. Allow engine to cool, then remove radiator cap slowly and add coolant to bring level up to over­ flow pipe.

FIGURE 7.

20

COOLING SYSTEM DRAIN LOCATIONS

AC GENERATOR There are no brushes, brush springs or collector rings on these generators, therefore they require very little servicing. Periodic inspections, to coincide with engine oil changes, will ensure good performance.

Radiator Fins and Hoses Every 500 hours or 3 months, clean the radiator fins of any restriction such as dust, leaves, mud, etc. with compressed air. Steam or water may be used instead of compressed air. At the same time, check coolant hoses for swelling, cracking or brittleness. Replace if necessary. Tighten hose clamps as needed.

Check generator voltage. It might be necessary to make a slight readjustment of the voltage rheostat to obtain the preferred voltage at average load.

Water Pump Every 4000 hours inspect the water pump for bearing play and for grease or water leakage. If a fault is detected, have the Onan Distributor disassemble and repair or replace the pump.

Inspection of Rotating Rectifier Assembly Move the control selector switch to STOP, disconnect the starting batteries, and then remove the generator grill section. Inspect the rotating rectifier assembly to make sure the diodes (see Figure 9) are free of dust, dirt, and grease. Excessive foreign matter on these diodes and heat sinks will cause the diodes to overheat and will result in their failure. Blow out the assembly periodically with filtered low pressure air.

BATTERIES Check the condition of the starting batteries at the interval specified in the maintenance table. See that connections are clean and tight. A light coating of non-conductive grease will retard corrosion at termi­ nals. Keep the electrolyte at the proper level above the plates by adding distilled water. Check specific gravity and recharge if below 1.260.

[ WARNING ' Accidental starting of the �et_ might cause severe personal mJury or death. Move the Operation Selector switch to STOP and disconnect the starting batteries before inspect­ Ing rotating rectifier assembly.

[ WARNING ' lg,:iition of explosive battery _ g�ses .______. might cause severe personal m1ury.

Do not smoke while servicing batteries.

ALTERNATOR AND FAN BELT Inspect the belts regularly for wear, cracks or fraying.

Replace if necessary. To check tension, first move the control selector switch to STOP. Then place a force of 13 pounds (6 kg) midway between the pulleys. If adjusted properly, the belt should deflect 3/8 inch (1 O mm).

ENDBELL

ARNING � Contact with rotating machinery !._.W____ .._ might cause serious personal Injury

or death. Be sure to move the Operation Selector switch to STOP before checking fan belt tension or before making any adjustments.

Be sure to loosen both the adjusting strap and bracket capscrews when making adjustments. Pull on the front alternator frame only to tighten the belt.

See Figure 8.

,/-

'-·);.;

\

\

CHECK TENSION HERE

OVERSPEED SWITCH

'

:.,

GENERATOR END VIEW (GRILLE REMOVED)

!.�

(.

ALTERNATOR •,

FIGURE 9.

CAPSCREWS

FIGURE 8.

ROTATING EXCITER WITH RECTIFIERS

ADJUSTING BELT TENSION

21

ROTATING RECTIFIER ASSEMBLY

Generator Bearing

Have the bearing inspected for wear every 2000 hours by an Onan service representative. If the unit is used for "prime power," have the bearing replaced every 10,000 hours or after two years. If the unit is used for "standby power," have the bearing replaced every five years.

AIR CLEANER

I

COVER

Two different styles of air cleaners are used. The style used on model DVC generator sets is shown in the upper drawing of Figure 10, the one used on models DVD and DVE in the lower drawing. They differ prim­ arily in physical dimension, but have the same service intervals. The filter element should be replaced yearly or sooner if the service indicator button pops up indicating air restriction.

On the larger filter, a vacuator valve dumps collected dust automatically.

The following procedure should be followed when replacing the element:

FLYWHEEL HOUSING DVC

1. Remove the air cleaner cover.

2. Remove thumb screw and gasket washer, then remove the element from air cleaner.

3. Wipe out the interior of the air cleaner housing and cover with a clean, damp cloth.

4. Install new element and secure with gasket washer and thumb screw.

5. Put on the air cleaner cover and secure.

CS-1269

!

COVER

WING NUT

Inspect all components of the air filtering system including all ducts and hoses. Verify that all connec­ tions and clamps are tight and inspect each compo­ nent for cracks, dents, or other damage. Repair or service as required.

VACUATOR VALVE

FLYWHEEL HOUSING DVD/DVE CS-1270

FIGURE 10. AIR CLEANER

22

TURBOCHARGER

VALVE CLEARANCES

Routine maintenance of the turbocharger should be completed every 1000 hours of operation. Call the Onan Distributor for maintenance as he has the knowledge and necessary tools for this procedure.

Special tools are required for removal and adjust­ ment of related parts. Have engine valve clearances checked and adjusted by the Onan Distributor as specified in the Maintenance Schedule.

Check the turbocharger daily for any exhaust leak­ age, air leakage, and for any oil leakage from the lubrication oil line. Oil leakage from the oil line (Fig­ ure 11) might cause bearings to seize. Leakage between the turbocharger and the intake manifold or exhaust manifold will cause performance reduction.

Any exhaust leakage must be corrected immediately.

I

VIBRATION DAMPER Check the damper every 2000 hours. See Figure 12. A match mark is imprinted on the hub and inertia member of the damper. Any divergence can be checked by this mark. Check also for any protrusion of rubber. If any abnormality is detected contact the Onan Distributor for service.

'Inhalation of exhaust gases might result In serious personal Injury or death. Inspect exhaust system audibly and visually for leaks daily. Repair any leaks Immediately.

WARNING

FIGURE 12. VIBRATION DAMPER

AIR FILTER EXHAUST OUTLET TURBOCHARGER

EXHAUST MANIFOLD

OIL LINE

"'-1

{

Onan Komatsu 0665T Diesel Generator Engine Parts Contact email: EngineParts@HeavyEquipmentRestorationParts.com Phone: 269 673 1638 Website: www.HeavyEquipmentRestorationParts.com

0

M-1591

FlGURE 11. TURBOCHARGER

23