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Onan DYG Series, Operator'S Manual And Parts Catalog

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Onan DYG Series Operator'S Manual And Parts Catalog Download Page 1

Summary of Contents for DYG Series

Page 1: ...R A T O R S M A N U A L A SERliS ELECTRIC GENERATING SETS 4 FORM NUMBER 973 0306 ISSUE DATE 6 77 Spec A F...

Page 2: ...d the system pressure first Protect Agamst Moving Parts Keep your hands away from moving parts Before starting work on the generating set disconnect batteries This will prevent starting the set accide...

Page 3: ...ations 1 5 0 1 7 5 kW 4 Specifications 2 0 0 kW 5 Description 8 installation 13 Electrical 1 5 0 1 7 5 kW 18 Electrical 2 0 0 kW 22 Operation 26 General Maintenance 32 Parts Catalog 34 WARNING TO AVOI...

Page 4: ...is necessary to contact a dealer or the factory regarding the set always mention the complete Model Spec No and Serial No as given on the Onan nameplate This nameplate information is necessary to prop...

Page 5: ...n arcing relays or brushes welding dropping a steel wrench on a concrete floor and of course a cigarette THIS DON T SMOKE IN THE VICINITY OF FUEL The following example is a vfery real possibility A lo...

Page 6: ...e Regulation 2 60 Hertz RPM 1800 50 Hertz RPM 1500 Output Rating 0 8 PF AC Frequency Regulation 3 Hz Max No load Full load CAPACITIES AND REQUIREMENTS Cooling System Including Radiator 16 5 Gallons 62...

Page 7: ...Voltage Regulation 2 60 Hertz RPM 1800 50 Hertz RPM 1500 Output Rating 0 8 PF AC Frequency Regulation 3 Hz Max No load Full load CAPACITIES AND REQUIREMENTS Cooling System Including Radiator 16 5 Gall...

Page 8: ...P FIGURE 1 STANDARD CONTROL PANEL ONE FAULT LAMP 150 175 kW D U A L R A N G E A C A M M E T E R I N D I C A T O R L A M P S I N D I C A T E U P P E R A N D L O W E R S C A L E O N V O L T M E T E R A...

Page 9: ...GAUGE WATER TEMPERATURE GAUGE FAULT LAMPS I STANDARD 5 OPTIONAL pc AMMETER RESET SWITCH FOR ENGINE MONITOR RUN STOP REMOTE SWITCH TEST LAMP BUTTON FIGURE 3 CONTROL PANEL AC VOLTMETER AC AMMETER VOLTA...

Page 10: ...ge instrument measurement range in use shown on indicator light AC Ammeter Indicates AC generator output current Dual range in use shown on indicator lights Voltmeter Ammeter Phase Selector Switch Sel...

Page 11: ...ection On standard control panels all four alarms are wired into one common fault lamp on units with five fault lamps four have shutdown alarms the fifth low engine temperature lights a fault lamp onl...

Page 12: ...X STANDARD Overcrank X X X SINGLE LIGHT Overspeed X X X Low Oil Pressure X X x High Engine femperature X X X 5 LIGHT Overcrank X X X Overspeed X X X Low Oil Pressure x X X High Engine Temperature X X...

Page 13: ...compensate for thermal expansion contraction It should also be able to absorb vibrations This is extremely important on turbo charged units where a rigid piece of exhaust pipe could impart enough str...

Page 14: ...A N V A S S E C T I O N C O O L I N G A I R I N L E T M U S T B E A T L E A S T P T I M E S L A R G E R T H A N R A D I A T O R D U C T O U T L E T A R E A O N R A D I A T O R C O O L E D M O D E L S...

Page 15: ...convenient preferably to the rearof the set Make the inlet opening at least as large as the radiator area preferably 1 1 2 times larger Engine heat is removed by a pusher fan which blows cooling air o...

Page 16: ...EXCHANGER SYSTEM On both systems use flexible pipe for connecting water supply and outlet flow pipes to engine Pipethe outlet flow to a convenient drain Install an electric solenoid valve and a rate o...

Page 17: ...artition Use a pipe at least as large as the 6 inch 152 mm pipe size outlet of the engine with a flexible portion between the engine and the muffler IF E X H A U S T LINE M U S T B E P I T C H E D U P...

Page 18: ...L I T R E WARNING It is necessary that an overflow pipe be installed between the day tank and main fuel tank A hazardous fire condition exists with spilled fuel I SIZE LARGER OVERFLOW FUELTRANSFER PUM...

Page 19: ...day tank installation BATTERY Starting the unit requires 24 volt battery current Use two 12 volt see Specifications batteries fora normal installation Connect the batteries in series negative post of...

Page 20: ...atic load transfer control are included with such equipment FIGURE 12 REMOTE STARTING L I N E L O A D G E N N O T E S H O W N W I T H L I N E C O N N E C T E D T O L O A D FIGURE 13 LOAD TRANSFER SWIT...

Page 21: ...515 1 2 0 2 4 0 115 230 1 1 0 2 2 0 6 0 H5 H6 H6 L 0 L l CT21 L 2 C T 2 2 T l T 2 T6T11 T 8 T 1 2 T 4 T 9 T5 T7 T 3 T I O 6D 15 2 4 0 4 8 0 1 2 0 2 4 0 6 0 6 0 H5 H5 515 115 230 1 1 0 2 2 0 H6 H 6 LO...

Page 22: ...acity of the set from any one circuit If using 1 phase and 3 phase current atthesametime use care to properly balance the 1 phase load and not to exceed rated line current Figure 18 shows load connect...

Page 23: ...X H5 220 380 50 Hz 3 238 X H3 230 400 50 Hz 3 226 X H4 9X 347 600 60 Hz 3 180 H3 Not Reconnectible 175 0 kW 145 0 kW TABLE 2A UR GENERATOR VOLTAGE OPTIONS 218 75 kVA 181 25 kVA 60 Hz 50 Hz VOLTS FREQ...

Page 24: ...be connected to a terminal marked H3 H4 or H5 depending upon the voltage option required Referto Table 3 and Figure 22 for voltages available and correct hookup WIRING CONNECTIONS Most local regulatio...

Page 25: ...60 50 50 50 50 H5 H4 H5 H3 H4 H4 H5 L Tl CT22 L 3 L 2 L l LO iZi 3 8 o 12 II IO 12 220 380 60 H3 17 240 416 254 440 277 480 60 60 60 H3 H4 H5 517 220 380 230 400 240 416 254 440 H3 H4 H4 H3 7 NOT RECO...

Page 26: ...x imum output RECONNECTION BAR STOWAGE 8 1 7 8 FIGURE 24 LOAD WIRE CONNECTIONS Bus bars and reconnection bars are aluminum plated with tin to retard electrolytic corrosion Select con necting cables an...

Page 27: ...3 60 Hz 656 AMPS X H4 139 240 3 60 Hz 600 AMPS X H5 240 416 3 60 Hz 347 AMPS X H3 254 440 3 60 Hz 328 AMPS X H4 277 480 3 60 Hz 300 AMPS X H5 YB517 110 190 3 50 Hz 616 AMPS X H3 115 200 3 50 Hz 598 A...

Page 28: ...nd before starting if the engine has not been run for 30 days or more Cooling System Cooling system was drained priorto shipment Fill cooling system before starting Nominal capacity is 16 5 gallons 62...

Page 29: ...er charge STARTING When the preceding service functions have been performed recheck to verify unit is ready to start 1 Crankcase filled 2 Cooling system filled inputsolenoid valveopen 3 Batteries char...

Page 30: ...ning for a period i 3 Check the following a Oil level Engine will shut down if sensor is closed b Check engine manual for troubleshooting oil system c High engine temperature Check coolant level check...

Page 31: ...ine c Refer to engine service manual for troubleshooting guide for oil system 4 High engine temperature shutdown 4 Check a Coolant level Replenish if necessary b City water cooled sets Check water flo...

Page 32: ...own engine and drain oil base while still warm Refill and attach a warning tag indicating viscosity of oil used 4 Service air cleaner 5 Clean throttle and governor linkage and protect by wrapping with...

Page 33: ...rflowbutusecaretoavoid overheating 5 Connect water jacket heater when set is not running 6 Refer to Allis Chalmers manual for further infor mation Water Jacket Heater The function of this optional hea...

Page 34: ...be required due to wear of internal components This adjustment is achieved by backing offthe high speed stop screw Screw in the low speed adjusting screw until the generator output frequency meter re...

Page 35: ...ers for possible leakage and cracks 3 Periodicallyordaily drain moisturefrom conden sation traps 4 Inspect water lines and connections for leaks and security 5 Inspect electrical wires and connections...

Page 36: ...3 6 153 0DYG 517R 153 000 50 12 3 7 200 0DYG 17R 200 000 60 12 3 8 The Specification Letter advances A to B B to C Z to AA etc with manufacturing changes These sets are reconnectible refer to Specifi...

Page 37: ...N NUMBER ELECTRIC GEN SET SERIAL NO IMPORTANT ALWAYS GIVE ABOVE NOS WHEN ORDERING PARTS MANUFACTURED BT ONAN DIV OF ONAN COIPORATION MINNEAPOLIS MINN 55432 U S A FOR EltCT EQUIPMENT N I 1 r I J 99A1C3...

Page 38: ...r Group 24 Volt Penn State Keys 1 2 3 4 5 6 69 Printed Circuit Board Assy Group Keys 1 2 3 4 5 6 Spec A through E 70 Printed Circuit Board Assy Group 332 1956 Begin Spec F 71 Remote Indicator Control...

Page 39: ...Unhoused Sets Only 14 SHROUD FAN 130 0841 1 Keys 1 2 3 4 5 6 130 0918 1 Keys 7 8 REF PART QTY NO NO USED 15 821 0014 6 16 130 0842 1 17 821 0016 4 18 870 0257 2 19 130 0848 2 20 800 0130 4 21 850 0070...

Page 40: ...MISCELLANEOUS ENGINE PARTS GROUP Includes Optionals 6 5 6 4 7 1 38...

Page 41: ...ating Fibre Nut Non Metallic Insulating Screw Cap Hex Head 1 4 20 x 1 Nut Hex 1 4 20 Washer Lock Spring 1 4 Washer Lock External Internal Tooth 1 4 45 193 0200 46 193 0029 47 504 0064 48 502 0118 49 5...

Page 42: ...CHASSIS GROUP KEYS 1 2 3 4 5 6 40...

Page 43: ...ad 1 4 20 x 1 2 800 0030 As Reqd Screw Cap Hex Head 5 16 18 x 1 1 4 800 0035 As Reqd Screw Cap Hex Head 5 16 18 x 2 1 2 800 0090 As Reqd Screw Cap Hex Head 1 2 13 x 1 800 0092 As Reqd Screw Cap Hex He...

Page 44: ...8 2 Keys 7 8 5 821 0030 1 Screw Cap Hex Head Locking 3 8 16 x 1 6 870 0281 5 Nut Hex Locking 3 8 16 7 821 0029 4 Screw Cap Hex Head Locking 3 8 16x3 4 8 140 1475 1 Bracket Air Cleaner 9 800 0031 2 Scr...

Page 45: ...ng 3 4 4 Nut Hex 3 4 10 2 Screw Cap Hex Head 3 4 10 x 1 1 2 Retainer Plate 1 Panel Front REF PART QTY NO NO USED 11 405 2016 1 13 301 3731 3 14 301 3605 1 15 301 3604 1 17 856 0006 2 18 234 0489 1 19...

Page 46: ...1856 1 Panel Rear Lower 6 405 1883 1 Housing Rear 7 405 1882 1 Housing Top 8 405 1875 8 Panel Louver 9 405 1877 4 Door Removable 10 405 1873 2 Panel Center 11 PANEL SIDE BRASS 405 2165 2 Begin Spec D...

Page 47: ...11 6 405 2014 7 405 2013 8 405 1880 9 406 0157 10 406 0089 11 405 1883 12 405 2016 13 405 1872 QTY PART USED DESCRIPTION 2 Panel Center 2 Panel Base 1 Panel Lower Rear Housing 2 Panel Rear Louver 4 Do...

Page 48: ...x 1 6 505 0740 1 Nipple Pipe 8 x 4 1 2 7 155 0652 2 Flange Companion 8 155 1404 1 Shield Muffler Heat 9 870 0188 1 Nut Hex Locking 10 32 10 155 1430 i 6 Spacer Muffler 11 505 0821 1 Nipple Pipe 6 x 6...

Page 49: ...Bushing Reducer Pipe Suction Plug Pipe Elbow Pipe Line Fuel Flexible Gauge Liquid Level Cap Tank Plug Pipe Tank Fuel 101 Gallon Plate End Sub Base 18 403 1003 1 Base Sub Fuel Tank 19 416 0446 1 Cable...

Page 50: ...le Line Fuel Flexible Connector Pipe Elbow Pipe 90 Plug Pipe 3 8 NPT Switch Fuel Level Cap Fuel Tank Plug Pipe 1 2 NPT 2 Strap Hold down 1 Tank Fuel 8 Gal REF NO 12 13 PART NO QTY USED PART DESCRIPTIO...

Page 51: ...4 0455 1 Screen Fan 7 232 2317 1 Spacer Bearing 22 800 0008 2 Screw Cap Hex Head 8 510 0106 1 Bearing 1 4 20 x 1 1 4 9 526 0252 1 Washer Flat 13 16 ID 23 862 0001 2 Nut Hex 1 4 20 x 2 3 8 OD x 5 32 Th...

Page 52: ...GENERATOR GROUP KEYS 1 2 3 4 5 6 11 10 50...

Page 53: ...16 x 5 3 4 21 812 0189 1 Screw Machine Round Head 3 8 16 x 3 4 22 856 0010 1 Washer Lock External Internal Tooth 3 8 23 150 0717 1 Switch Overspeed 24 800 0008 2 Screw Cap Hex Head 1 4 20 x 1 1 4 25...

Page 54: ...VOLTAGE REGULATOR GROUP KEY 1 2 3 4 5 6 SPEC A THROUGH C 2 2 7 8 1 4 1 5 1 6 1 7 1 8 1 9 2 0 1 4 1 5 1 6 1 7 52...

Page 55: ...tWasher Flat Brass 172 I D x 3 8 O D x 1 32 Thkf 16 853 0005 2 tWasher Lock External Tooth 8 REF PART QTY PART NO NO USED DESCRIPTION 17 871 0007 2 tNut Hex Rectifier Lead to Heat Sink 8 32 18 812 007...

Page 56: ...BUS BAR GROUP KEYS 7 8 17 f_ 2 3 n 2 0 f 9 4 6 4 7 4 8 4 9 3 4 3 5 3 6 3 7 3 3 4 2 4 3 4 4 4 5 r 54 55 56 3 8 3 9 4 0 4 1 I 5 7 5 8 5 9 54...

Page 57: ...27 232 2243 2 Board Insulating 28 232 2242 2 Board Insulating 29 232 2343 3 Bar Bus 30 232 2241 11 Bar Bus REF PART QTY PART NO NO USED DESCRIPTION 31 232 2240 4 Bar Bus 32 232 2238 1 Bracket Bus Bar...

Page 58: ...e Round Head 10 32 x 1 2 Washer Flat 13 64 ID x 7 16 OD x 1 32 Thk Washer Lock Spring 10 Nut Hex 10 32 Screw Machine Round Head 10 32 x 2 REF PART QTY PART NO NO USED DESCRIPTION 11 526 0009 4 Washer...

Page 59: ...0053 4 11 SINK HEAT 363 0049 1 363 0050 1 12 508 0093 2 13 332 0050 2 PART DESCRIPTION Rotor Assembly Exciter Complete Also shown in Generator Group Positive Stud Negative Stud Washer Lock Spring 1 4...

Page 60: ...CONTROL GROUP Engine Portion KEYS 1 2 3 4 5 6 o r rA 58...

Page 61: ...Approved 1 Light HARNESS ASSEMBLY WIRING CONTROL Includes Parts Marked t 338 0528 1 Sets With One Fault Light Standard 1 Sets With Five Fault Lights Optional 1 fBoard Terminal 4 Place 338 0534 20 332...

Page 62: ...TROL GROUP Engine instruments Portion KEYS 7 8 t 2 4 1 2 6 o d O o E J 1 i y L IDD M I M M X o T r 1 3 5 60 t 3 4 o l t r l c OD HO 9 p omD EO flllll o I 0 0 ft frjry o o OBD HO I k oa o cztn 1 3 3 32...

Page 63: ...crank Optional 322 0123 1 Overspeed Optional 322 0120 1 Low Oil Pressure Opt 322 0121 1 High Engine Temperature Optional 322 0122 1 Low Engine Temperature Optional REF PART QTY PART NO NO USED DESCRIP...

Page 64: ...CONTROL GROUP AC Output Portion KEYS 1 2 3 4 5 6 21...

Page 65: ...20 21 22 23 24 25 26 27 302 0221 302 0256 AMMETER 302 0723 302 0411 302 0724 302 0412 1 Meter Electrical Frequency 60 Hertz 1 Meter Electrical Frequency 50 Hertz 1 Key 1 1 Key 3 1 Key 2 4 and 6 1 Key5...

Page 66: ...CONTROL GROUP AC Portion KEYS 7 8 6 64...

Page 67: ...Bracket Relay Mounting 17 315 0384 1 Reactor Assembly Comm 18 307 1157 1 Spring Relay Holddown 19 303 0170 1 Rheostat Voltage Adj 20 303 0032 1 Knob Rheostat 21 350 0556 1 Resistor 22 315 0431 1 23 3...

Page 68: ...ENGINE CONTROL MONITOR GROUP 24 VOLT OPTIONAL EQUIPMENT KEYS 1 2 3 4 5 6 5 Fault Lights Kt i 2PX Iwi W CB M tt n IS W H K III K H 6 7 t 5 4 3 Z l 3 0 0 0 6 8 2 66...

Page 69: ...1 Mfd 35 Volt C5 355 0005 1 Capacitor Plastic Dielectric C6 22 Mfd 200 VDC 10 C6 355 0005 1 Capacitor Plastic Dielectric C7 22 Mfd 200 VDC 10 C7 355 0005 1 Capacitor Plastic Dielectric 22 Mfd 200 VDC...

Page 70: ...Resistor 10 000 Ohm 350 0980 1 Resistor 510 Ohm 350 0380 1 Resistor 510 Ohm 350 0544 2 Resistor 4 700 Ohm 350 0529 2 Resistor 270 Ohm 350 0587 1 Resistor 18 Megohm 350 0517 1 Resistor 27 Ohm 350 0505...

Page 71: ...004 1 Diode Rectifier R8 400 MA 400 Volt CR6 357 0004 1 Diode Rectifier R9 400 MA 400 Volt CR7 364 0011 1 Diode Rectifier R10 8 Amp 30 Volt Kl 307 1076 1 Relay Armature 24 Volt R11 K2 307 1076 1 Relay...

Page 72: ...Silicon NPN Q3 361 0004 1 Transistor Unijunction Rl R23 350 0355 2 Resistor 47 Ohm 1 2 Watt R2 R3 350 0351 2 Resistor 33 Ohm 1 2 Watt R4 350 1075 1 Resistor 4 7 Megohm 2 Watt R5 353 0040 1 Resistor F...

Page 73: ...0 1011 2 Fl F2 F3 321 0204 3 Fuse 1 4 Amp R26 303 0211 1 I C I 367 0005 1 Integrated Circuit 303 0211 1 02 362 0017 1 Transistor Silicon NPN R28 350 0568 332 1252 1 1 i 03 361 0004 1 Transistor Unijun...

Page 74: ...Diode 400 MA 400 Volt Rectifier Gate Control Transistor PNP Resistor 270 Ohms 1 2 Watt Resistor 4 700 Ohms 1 2 Watt Resistor 2 700 Ohms 1 2 Watt Resistor 510 Ohms 1 2 Watt Resistor 27 Ohms 1 2 Watt R...

Page 75: ...0512 2 Resistor 10 Ohm 1 2 Watt 355 0057 1 Capacitor 47 Mfd 100 VDC STARTING MOTOR DISCONNECT MODULE KEYS 7 8 6 r ICI C2 CRl c 3B4 CR2 S o i r o n 1C8 CM NO 1 CR3 1C2 7 r LRS 21 t l to I M IT c T T T...

Page 76: ...r 220 Ohms 1 2 Watt R9 17 350 0540 2 Resistor 2200 Ohms 1 2 Watt R14 16 303 0169 2 Potentiometer 3 5 Megohm R23 11 350 0545 2 Resistor 5600 Ohm 1 2 Watt O R2 4 CR _ R2 izr Q U CRIO H R5 r ZT Cl R U i...

Page 77: ...52 0155 1 R I I 350 0534 1 C1 355 0029 1 PART DESCRIPTION Module Cycle Cranker Capacitor Composition 0022 Mfd lOOVolt Capacitor Electrolytic lOO Mfd 10 Volt Capacitor Electrolytic 25 Mfd 15 Volt Diode...

Page 78: ...itor Electrolytic 25 Mfd 15 Volt 1 Capacitor Composition 015 Mfd 100 Volt 1 Resistor Fixed 5 Watt lOO Ohm 1 Resistor Fixed Composition 1 0 Ohm 1 Resistor Fixed 6 8 Ohm 1 Resistor Fixed Composition 6 8...

Page 79: ...Order 17 of Bulk Hose 503 0386 9 505 0039 1 Elbow Pipe 3 8x90 11 520 0446 2 Stud 12 850 0030 2 Washer Lock 10 13 870 0053 2 Nut Hex 10 32 14 309 0106 1 Thermostat 15 333 0012 1 Box Thermostat 16 333 0...

Page 80: ...23 862 0015 1 24 130 0755 1 PART DESCRIPTION Heater Water Jacket 2000 Watt 240 Volt Nipple Half 3 8 x 1 1 2 Clamp Hose Hose Order 19 of Bulk Hose 503 0386 Valve Drain Tee Pipe 3 8 Nipple Close 3 8 x...

Page 81: ...olt Switch Oil Pressure Support Pressure Switch Elbow Pipe 90 1 4 NPTx 5 16 SAE Line Flexible 24 Lg Nipple Pipe Close 1 8 NPT x 3 4 Relay 480 Volt 30 Amp Thermostat Clamp Hose Hose Rubber Order 35 of...

Page 82: ...Pipe Nipple Assembly 7 800 0007 6 Screw Cap Hex Head 1 4 20 x 1 8 850 0040 6 Washer Lock Spring 1 4 9 862 0001 6 Nut Hex 1 4 20 10 505 0175 1 Elbow Pipe 2 NPT x 90 i i 505 0172 i Nipple Pipe Close 2...

Page 83: ...800 0058 1 18 307 0844 19 309 0245 1 PART DESCRIPTION Guard Belt Screw Cap Hex Head 1 2 13 x 1 1 2 Washer Lock Spring 1 2 Nut Hex 1 2 13 Plate Mounting Solenoid Bracket and Pipe Nipple Assembly Screw...

Page 84: ...2 130 0797 1 Bracket and Pipe Nipple 34 503 0631 Assembly 35 505 0204 13 800 0007 4 Screw Cap Hex Head 1 4 20 x 1 36 505 0140 14 850 0040 4 Washer Lock Spring 1 4 37 505 0764 15 862 0001 4 Nut Hex 1 4...

Page 85: ...bly Screw Cap Hex Head 1 4 20 x 1 Washer Lock Spring 1 4 Nut Hex 1 4 20 Support Standpipe Valve Drain Base Standpipe Screw Cap Hex Head 1 2 13 x 1 1 2 Washer Lock Spring 1 2 REF PART NO NO 21 865 0005...

Page 86: ...lve Drain 18 130 0442 1 Base Standpipe 19 800 0092 9 Screw Cap Hex Head 1 2 13x1 1 2 20 850 0060 9 Washer Lock Spring 1 2 21 862 0005 8 Nut Hex 1 2 13 22 505 0421 1 Nipple Pipe 2 x 8 REF PART QTY PART...

Page 87: ...ve Drain 18 130 0442 1 Base Standpipe 19 800 0092 9 Screw Cap Hex Head 1 2 13 x 1 1 2 20 850 0060 9 Washer Lock Spring 1 2 REF PART QTY PART NO NO USED DESCRIPTION 21 862 0005 8 Nut Hex 1 2 13 22 505...

Page 88: ...Qnan I400 73RD AVE NU E 55432 A DIVISION OF ONAN CORPORAtlON J...

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