Onen Installation Manual DF Series GENERATOR SETS Printed USA. 960.0615 9.95Table of Contents SECTION TILE PAGE SAFETY PRECAUTIONS .. INTRODUCTION About this Manual... Installation Overview SPECIFICATIONS . 5 MOUNTING THE GENERATOR SET General Location Mounting ...... ‘Access to Set Vibration Isolators... ‘Aligning Generator with Engine (750 KW Gensets and Larger) . MECHANICAL CONNECTIONS General .. Fuel System ..... Exhaust System Ventilation and Cooling . Lubrication .. Coolant Fuel DC CONTROL WIRING (pce) Control Wiring .... B1 Remote Moritor/Control Connections Run Relays ........ Alarm Relay (K14) RTD Relay (Optional) ‘Thermistor Relay (Optional) DC CONTROL WIRING (DETECTOR CONTROL) Control Wiring Engine Monitor Board (ECM-A11) . Auxiliary Relay board (Optional) Time-Delay Module (A15) oe RTD Relay (Optional) .... a Thermistor Relay (Optional)7 10 ‘AC ELECTRICAL CONNECTIONS General .. wTA Insulation Resistance (Megger) & Polarization Index (Pl) Testing ....... 7-2 Transfer Switch . a foes ‘AC Wiring ... Control Heater (Optional) Coolant Heater .. Generator Heater Fuel Transfer Pump ....... Ground Fault Alarm Relay (Optional) PRESTART PREPARATION (PCC) General - Ventilation .. Exhaust System . Mechanical Checks Electrical System . PCC Power On/Auto Mode PCC Options Prestart Checks Starting : PRESTART PREPARATION (DETECTOR CONTROL) General .. Ventilation Exhaust System Mechanical Checks Electrical System Starting ....... INSTALLATION CHECKLIST 94 cee eee eee PZ General 10-4 Genset Support . 10-4 Cooling Air Flow . : 10-1 Diesel Fuel System 10-1 Exhaust System = 10-2 AC and DC Wiring . ce 10-2 Genset Prestart : 10-2 WIRING DIAGRAMS General . California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.Safety Precautions Before operating the generator set, read the Op- erator’s Manual and become familiar with it and the equipment. Safe and efficient operation can be achieved only If the equipment Is properly oper- ated and maintained. Many accidents are caused by failure to follow fundamental rules and precau- tions. The following symbols, found throughout this man- ual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment. FSGINEEA This symbol warns of immediate hazards which will result In severe personal in- jury or death. (AWARNING] This symbol refers to a hazard or un- safe practice which can result in severe per- sonal injury or death. [ACAUTION] This symbol refers toa hazard or un- safe practice which can result in personal injury or product or property damage. FUEL AND FUMES ARE FLAMMABLE. Fire, explosion, and personal injury or death can re- sult from improper practices. * DO NOT fill fuel tanks while engine is running, unless tanks are outside the engine compart- ment. Fuel contact with hot engine or exhaust is a potential fire hazard. ‘* DONOT permit any flame, cigarette, pilot light, spark, arcing equipment, or other ignition source near the generator set or fuel tank. * Fuel lines must be adequately secured and free of leaks. Fuel connection at the engine ‘should be made with an approved flexible line. Do not use copper piping on flexible lines as copper will become brittle if continuously vi brated or repeatedly bent. © Be sure all fuel supplies have a positive shutoff valve. * Be sure battery area has been well-ventilated prior to servicing near it. Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by arcing, sparking, smoking, ete. EXHAUST GASES ARE DEADLY Provide an adequate exhaust system to prop- erly expel discharged gases away from en- closed or sheltered areas and areas where in- dividuals are likely to congregate. Visually and audibly inspect the exhaust daily for leaks per the maintenance schedule. Ensure that ex- haust manifolds are secured and not warped. Do not use exhaust gases to heat a compart- ment. * Be sure the unit is well ventilated. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH * Keep your hands, clothing, and jewelry away from moving parts. * Before starting work on the generator set, dis- ‘connect battery charger from its AC source, then disconnect starting batteries, negative (-) cable first. This will prevent accidental starting. ‘¢ Make sure that fasteners on the generator set are secure. Tighten supports and clamps, keep guards in position over fans, drive belts, etc. ‘* Do not wear loose clothing or jewelry in the vi- cinity of moving parts, or while working on elec trical equipment. Loose clothing and jewelry ‘can become caught in moving parts. Jewelry can short out electrical contacts and cause shock or burning © If adjustment must be made while the unit is running, use extreme caution around hot mani- folds, moving parts, etc. Ls-10ELECTRICAL SHOCK CAN CAUSE SEVERE PERSONAL INJURY OR DEATH ‘+ Remove electric power before removing pro- tective shields or touching electrical equip- ment. Use rubber insulative mats placed on dry wood platforms over floors that are metal or concrete when around electrical equipment. Do not wear damp clothing (particularly wet shoes) or allow skin surface to be damp when handling electrical equipment. + Use extreme caution when working on electri- cal components. High voltages can cause in- jury or death. DO NOT tamper with interlocks, * Follow all applicable state and local electrical codes. Have all electrical installations per- formed by a qualified licensed electrician. Tag open switches to avoid accidental closure. * DO NOT CONNECT GENERATOR SET DI- RECTLY TO ANY BUILDING ELECTRICAL SYSTEM. Hazardous voltages can flow from the generator set into the utility fine. This cre- ates a potential for electrocution or property damage. Connect only through an approved isolation switch or an approved paralleling de- vice. HIGH VOLTAGE GENERATOR SETS (1.9kV to 15kV) * High voltage acts differently than low voltage. Special equipment and training is required to work on or around high voltage equipment. Op- eration and maintenance must be done only by persons trained and qualified to work on such devices. Improper use or procedures will result in severe personal injury or death. ‘* Do not work on energized equipment. Un- authorized personnel must not be permitted near energized equipment. Due to the nature of high voltage electrical equipment, induced voltage remains even after the equipment is disconnected from the power source. Plan the time for maintenance with authorized person- nel so that the equipment can be de-energized and safely grounded. GENERAL SAFETY PRECAUTIONS Coolants under pressure have a higher boiling point than water. DO NOT open a radiator or heat exchanger pressure cap while the engine is running. Allow the generator set to cool and bleed the system pressure first. Benzene and lead, found in some gasoline, have been identified by some state and federal agencies as causing cancer or reproductive toxicity. When checking, draining or adding gasoline, take care not to ingest, breathe the fumes, or contact gasoline. Used engine oils have been identified by some state or federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil Provide appropriate fire extinguishers and ‘n- stall them in convenient locations. Consutt the local fire department for the correct type of 2x- tinguisherto use. Do not use foam on electrical fires. Use extinguishers rated ABC by NFPA. Make sure that rags are not left on or near the engine. Remove all unnecessary grease and oil from the unit. Accumulated grease and oil can cause overheating and engine damage which present a potential fire hazard. Keep the generator set and the surrounding area clean and free from obstructions. Re- move any debris from the set and keep the floor clean and dry. Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe. ‘Substances in exhaust gases have been iden- tifled by some state or federal agencies as ‘causing cancer or reproductive toxicity. Take care notto breath oringest or come into contact with exhaust gases. KEEP THIS MANUAL NEAR THE GENSET FOR EASY REFERENCE1. Introduction ABOUT THIS MANUAL, This manual provides installation instructions for the DF Series generator sets. This includes the fol towing information: Mounting Recommendations - for fastening generator set to base and space requirements, for normal operation and service. Mechanical Connections - Location of con- nection points for fuel, exhaust, ventilation, and cooling, Electrical Connections — Location of electri- cal connection points forthe control, generator, and starting system. Prestart — Checklist of items or procedures needed to prepare generator set for operation Initial Startup ~ Test complete system to en- sure proper installation, satisfactory perform- ance, and safe operation. Refer to Operators Manual for troubleshooting information. ‘This manual contains separate DC Control! Wir- ing and Initial Start and Checks sections for gensets using the standard Powercommand™ Control (PCC) and the optional Detector control (Figure 1-1). Refer to the Table of Contents tor specific information relating to your genset. All other sections apply to both versions. This manual DOES NOT provide application infor- mation for selecting a generator set or designing the complete installation. Ifitis necessary to design the various integrated systems (fuel, exhaust, cooling, etc.), review standard installation practices, or ‘specify system materials, additional information is required. For engineering data specific to the gen- erator set, refer to the specification and product data sheets. For application information, refer to Application Manual 1-030, "Liquid Cooled Genera- tor Sets", available from Onan. Detector 12 Control FIGURE 1-1. CONTROL PANEL CONFIGURATIONS.INSTALLATION OVERVIEW ‘These installation recommendations apply to typi- cal installations with standard model generator sets. Whenever possible, these recommendations also cover factory designed options or modifica- tions, However, because of the many variables in any installation, it is not possible to provide specific recommendations for every situation. If there are any questions not answered by this manual, contact an Onan distributor for assistance. Application and Installation A standby power system must be carefully planned and correctly installed for proper operation. Thisin- volves two essential elements: application and in- stallation. Application (as it applies to generator set installa- tions) refers to the design of the complete standby power system that usually includes power distribu- tion equipment, transfer switches, ventilation equip- ment, mounting pads, and cooling, exhaust, and fuel systems. Each component must be correctly designed so the complete system will function as in- tended. Application and design is an engineering function generally done by specifying engineers or other trained specialists. Specifying engineers are responsible for the design of the complete standby system and for selecting the materials and products required. Installation refers to the actual set-up and assem- bly of the standby power system. The installers set up and connect the various components of the sys- tem as specified in the system design plan. The complexity of the standby system normally requires the special skills of qualified electricians, plumbers, sheetmetal workers, etc. to complete the various segments of the installation. This is necessary so all components are assembled using standard methods and practices. Safety Considerations The generator set has been carefully designed to provide safe and efficient service when properly in- stalled and operated. However, the overall safety ‘and reliability of the complete system is dependent ‘on many factors outside the control of the generator set manufacturer. To avoid possible safety haz- ards, make all mechanical and electrical connec- tions to the generator set exactly as specified in this manual. All systems external to the generator (fuel, ‘exhaust, electrical, etc.) must comply with all appli- cable codes. Make certain all required inspections and tests have been completed and alll code re- quirements have been satisfied before certifying the installation is complete and ready for service.2. Specifications IMPORTANT DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR CON- STRUCTION PLANS. 2 coeeemea 00 Bean Gots) | Zon bras (Sore) | 220 rac 50 Hs ‘Cummins Model Engine LTA10-G1 (60 Hz) | LTA10-G1 (60 Hz) LTA10-Gi1 (60 Hz) LTA10-G3 (50 Hz)_| _LTA10-G3 (50 Hz) LTA10-G3 (50 Hz) Coolant Capacity Engine and Radiator 13 Gal (49 L) 13 Gal (49 L) 13 Gal (49 L) ll Capacity 9.5 Gal. (36 L) 9.5 Gal. (36 L) 9.5 Gal. (36 L) Fuel Pump Inlet Thread Size 718-14 UNF 718-14 UNF 7/8-14 UNF Outlet Thread Size 3/4-16 UNF 3/4-16 UNF 3/4-16 UNF Maximum Fuel Lift 5 ft (1.5m) 5 ft (1.5m) 5 ft (1.5m) Exhaust Outlet Size 4in NPT 4in NPT 4in NPT Maximum Allowable 40.8 in H20 40.8 in H20 40.8 in H20 Back Pressure (10.2 kPa) (10.2 kPa) (10.2 kPa) Electrical System Starting Voltage 24 Volts DC 24 Volts DC 24 Volts DC Battery ‘Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D Cold Cranking Amps 975 975 975 24Genset Model 275 DFBF 300 DFCB 350 DECC Cummins Model Engine NT@55-G6 NTA855-G2 NTA855-G3 ‘Coolant Capacity Engine and Radiator 16.5 Gal. (62.5 L) 17 Gal, (64.4 L) 7 Gal. (64.41) Oil Capacity 10.5 Gal. (40 L) 10.5 Gal. (40 L) 10.5 Gal, (40 L) Fuel Pump Inlet Thread Size 718-14 UNF 7/8-14 UNF 718-14 UNF. Outlet Thread Size 3/4-16 UNF 3/4-16 UNF 3/4-16 UNF Maximum Fuel Lift 5 ft (1.5m) 5 ft (1.5m) 5 ft (1.5m) Exhaust Outlet Size SinNPT 6 in NPT 6 in NPT Maximum Allowable 40.8 in H,0 40.8 in Hz0 40.8 in Hz0 Back Pressure (10.2 kPa) (10.2 kPa) (10.2 kPa) Electrical System Starting Voltage 24 Volts DC 24 Volts DC 24 Volts DC Battery Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D Cold Cranking Amps 975 975 975 Genset Model 400 DFEB 450 DFEC 500 DFFB ‘Cummins Model Engine KTA19-G2 KTA19-G3 KTTAI9-G2 Coolant Capacity Engine and Radiator 24 Gal. (91 L) 24 Gal. (91 L) 24 Gal. (91 L) Oil Capacity 12 Gal. (45 L) 12 Gal. (45 L) 12 Gal. (45 L) Fuel Pump, Inlet Thread Size 718-14 UNF 718-14 UNF 718-14 UNF Outlet Thread Size 3/4-16 UNF 3/4-16 UNF 9/416 UNF Maximum Fuel Lift 6 ft (1.8m) 6 ft (1.8m) 6 ft (1.8m) Exhaust Outlet Size 5in NPT 6in NPT 6 in NPT Maximum Allowable 40.8 in H20 40.8 in H20 40.8 in H20 Back Pressure (10.2 kPa) (10.2 kPa) (10.2 kPa) Electrical System Starting Voltage 24 Volts DC 24 Volts DC 24 Volts DC Battery Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D Cold Cranking Amps 975 975 975 2-22-3 Genset Model 500 DFGA 600 DFGB ‘Cummins Model Engine VTA28-G5 ‘VTA28-G5 Coolant Capacity Engine and Radiator 44 Gal. (167 L) 44 Gal. (167 L) Oil Capacity 22.25 Gal. (84 L) 22.25 Gal. (84 L) Fuel Pump Inlet Thread Size 1-1/16-14 UNF, 45° 1-1/16-14 UNF, 45° Outlet Thread Size 3/4-16 UNF, 45° 3/4-16 UNF, 45° Maximum Fuel Lift 6 ft (1.8m) 6 ft (1.8m) Exhaust Outlet Size 5 in NPT Sin NPT Maximum Allowable 41 in H20 41 in H0 Back Pressure (10.2 kPa) (10.2 kPa) Electrical System Starting Voltage 24 Volts DC 24 Volts DC Battery ‘Two, 12 Volt, Type 8D | Two, 12 Volt, Type 8D Cold Cranking Amps 975 975 Genset Model 750 DFJA 800 DFJB 900 DFC 1000 DFJD ‘Cummins Model Engine | _KTA38-G1 KTA38-G2 KTA36-G3_| KTTA38-G4 (G5)' Coolant Capacity Engine and Radiator __| 81.5 Gal. (308 L) | 85.3 Gal. (323 L) | 85.3 Gal. (323 L) | 88.9 Gal. (637 L) Oil Capacity ‘Standby 34Gal. (129 L) | 34Gal. (1291) | 34Gal. (1291) | 34Gal. (1291) Prime 44 Gal. (1551) | 41 Gal (1551) | 41 Gal. (1551) | 41 Gal. (155 L) Fuel Pump Inlet Thread Size 1-5/16-12 UNF | 1-5/16-12 UNF | 1-5/16-12 UNF | 1-5/16-12 UNF. Outlet Thread Size 718-14 UNF 718-14 UNF 718-14 UNF 718-14 UNF Maximum Fuel Lift 6 ft (1.8m) 6 ft (1.8m) 6 ft (1.8m) 6 ft (1.8m) Exhaust Outlet Size 6 in. flange 6 in. flange 6 in. flange Maximum Allowable 41 in HO 41 in H20 41 in H20 Back Pressure (10.2 kPa) (10.2 kPa) (10.2 kPa) (10.2 kPa) Electrical System Starting Voltage 24 Volts DC 24VoltsDC | 24VoltsDC | 24 Volts DC Battery Four, 12 Volt, | Four 12 Volt, | Four, 12 Volt, | Four, 12 Volt, ‘Type 8D ‘Type 8D ‘Type 8D Type 8D Cold Cranking Amps 975 975 975 9751100 DFLB. 1250 DFLC 1200 DFLD 1500 DFMB ‘Cummins Model Engine | _ KTA50-G2 KTA50-G4 KTA50-G4 KTTAS0-G2 Coolant Capacit Engine and Radiator 92 Gal. (348 L) | 102 Gal. (386 L) | 102 Gal. (386 L) | 102 Gal. (386 L) Oil Capacity ‘Standby 44,7 Gal. (169 L) | 44.7 Gal. (169 L) | 44.7 Gal. (169 L) | 44.7 Gal. (169 L) Prime 58.7 Gal. (222 L) | 58.7 Gal. (222 L) | 58.7 Gal. (222 L) | 58.7 Gal. (222 L) Fuel Pump Inlet Thread Size 1-6/16-12 UNF | 1-5/16-12 UNF | 1-5/16-12 UNF | 1-5/16-12 UNF Outlet Thread Size 718-14 UNF 718-14 UNF 718-14 UNF 718-14 UNF Maximum Fuel Lift 6 tt (1.8m) 6 ft (1.8m) 6 ft (1.8m) 6 ft (1.8m) Exhaust Outlet Size 6 in. flange 6 in. flange 6 in. flange Maximum Allowable 41 in HO 41 in HO 41 in H20 Back Pressure (10.2 kPa) (10.2 kPa) (10.2 kPa) (10.2 kPa) Electrical System Starting Voltage 24 Volts DC 24VoltsDC | 24VoltsDC | 24 Volts DC Battery Four, 12 Volt, | Four 12 Volt, | Four, 12 Volt, | Four, 12 Volt, Type 8D ‘Type 8D Type 8D ‘Type 8D Cold Cranking Amps 975 975 975 975 2-43. Mounting the Generator Set GENERAL Most generator set installations must be engi- neered so the generator set will function properly under the expected load conditions. Use these in- structions as a general guide only. Follow the in- structions of the consulting engineer when locating or installing any components. The complete instal- lation must comply with all local and state building codes, fire ordinances, and other applicable regula- tions. Requirements to be considered prior to installation: * Level mounting surface + Adequate cooling air ‘© Adequate fresh induction air Discharge of circulated air [AWARNING] ‘* Discharge of exhaust gases ‘* Electrical connections ‘* Accessibility for operation and servicing + Noise levels * Vibration isolation LOCATION Generator set location is decided mainly by related systems such as ventilation, wiring, fuel, and ex- haust. The set should be located as near as possi- bie to the main power fuse box. Provide a location away from extreme ambient tem- peratures and protect the generator set from ad- verse weather conditions. An optional housing is available for outside operation. INCORRECT INSTALLATION, SERVICE OR REPLACEMENT OF PARTS CAN RESULT IN SE- VERE PERSONAL INJURY OR DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PERSON- NEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND MECHANICAL COMPONENT INSTALLATION. IMPORTANT DEPENDING ON YOUR LOCATION AND INTENDED USE, FEDERAL, STATE OR LOCAL LAWS AND REGULATIONS MAY REQUIRE YOU TO OBTAIN AN AIR QUALITY EMISSIONS PERMIT BEFORE BEGINNING INSTALLATION OF YOUR GENSET. BE SURE TO CONSULT LOCAL POLLUTION CONTROL OR AIR QUALITY AUTHORITIES BEFORE COMPLETING YOUR CON- STRUCTION PLANS. 341MOUNTING Generator sets are mounted on a steel subbase that provides proper support. For critical installa- tions, install vibration isolators between the sub- base and the foundation ‘Mount the generator set on a substantial and level base such as a concrete pad. For typical installa- tions, use 3/4 inch anchored mounting bolts to se- cure the generator set subbase to the floor to pre- vent movement. Secure the subbase/vibration iso- lators using flat or bevel washer and hexagonal nut for each bolt (see Figure 3-1). for proper spacing of ‘mounting bolts and set mounting dimensions, see your generator set outline drawing. ACCESS TO SET Plan for access to the genset for servicing and pro- vide adequate lighting around the unit. For conven- ience in general servicing such as the radiator, fan belt and changing the crankcase oil, the surface of the mounting base should be at least 6 inches (152 mm) above the floor. 3-2 FLAT OR BEVEL WASHER 1-172x6 INCH PIPE 12IN (805 mm) CONCRETE FIGURE 3-1. BOLT DIAGRAMMUFFLER, THIMBLE ‘AC POWER WIRING IMPORTANT! COOLING AIR INLET MUST BE AT LEAST 1-1/2 TIMES LARGER THAN RADIATOR DUCT OUTLET AREA. ‘ON RADIATOR COOLED MODELS. FLOW OF COOLING AIR AND HEATED AIR CAN BE CONTROLLED BY AUTOMATICALLY OPERATED LOUVRES FIGURE 3-2. TYPICAL INSTALLATION 3-3VIBRATION ISOLATORS Installation and Adjustment Procedure 1. Place the vibration isolators (Figure 3-3) on the genset support structure. The isolators should be shimmed or grouted to ensure that all of the isolator bases are within 0.25 inch (6 mm) ele- vation of each other. The surface that the isola- tor bases rest on must also be flat. 2. Loosen the side snubber lock nuts so that the top plate of the isolator is free to move vertically and horizontally. Be sure that the top plate is, correctly aligned with the base and springs. 3. Place the genset onto the isolators while align- ing the skid’s mounting with the threaded isola- tor hole. The top plates will move down and ap- proach the base of the isolator as load is ap- plied. 4, Once the genset is in position, the isolators may require adjusting so that the set is level. GENSET SKID The isolators are adjusted by inserting the lev- eling bolt through the skid and into the isolator (the leveling bot’s locking nut should be threaded up towards the bolt head). ‘The leveling bot will adjust the clearance be- tween the top plate and the isolator base. A nominal clearance of 0.25 inch (6 mm) or greater is desired. This will provide sufficient clearance for the rocking that occurs during startup and shutdown. If the 0.25 inch (6 mm) clearance is not present, tum the leveling bolt until the desired clearance is achieved. 5. The genset may not be level yet; therefore, ad- just the leveling bolts until the set is level and sufficient clearance still remains. Once all iso- lators have been set, lock the leveling bolt in place with the lock nut. 6. The snubber nuts may remain loose and there- fore provide better isolation between the gen- set and support structure. FIGURE 3-3. VIBRATION ISOLATORSAl IGNING GENERATOR WITH ENGINE, (750 kW GENSETS AND LARGER) Proper alignment of the generator and engine as- sembliesis necessary to avoid premature wear and improper operation of the genset. Review the fol lowing alignment conditions and procedures for aligning the generator assembly to engine flywheel housing. Angular Alignment Angular alignment is the result of the generator bearing center axis not aligning with axis of the en- gine crankshaft. This condition creates an angle between the generator shaft axis and the crank- shaft axis. The cause of this type of misalignmentis usually shimming ertor. Axial Misalignment ‘Axial misalignment is the result of the generator shaft axis not aligning with engine crankshatt axis. The tolerances in the bolted flywheel and drive disc connection may add up to displace the generator axially relative to the crankshaft axis. Misalignment Symptoms Ifthe assembly is allowed to run under these condi- tions, the discs must flex in alternate directions revolution. It is important to minimize the amount of disc flexing since, if itis ex- cessive, the drive disc will crack. Although perfect bearing alignment is desirable, it is more important to keep disc deflection to the very minimum possi- ble. This procedure assumes that the pilot bore of the drive discs are in the exact center and the fly- wheel counterbore (pilot) has no practical runout. Under these conditions, perfect Angular alignment will be attained when no deflection of the discs is measured. Excessive Axial alignment will cause more genera- tor vibration than Angular misalignment. Axial misalignment should be checked only when an objectionable vibration is present. Either type off misalignment may be present in a generator set assembly, with angular misalignment being the most common problem. Angular align- ment may also be effected by set ti tions and/or mishandling during shipping of the gen- set. SEE DETAIL A Cl { - ‘CLAMP _DIAL INDICATOR 7 | ah é 1 FLEX a E biscs ° = 3 GENERATOR MOUNTING BOLT oH AND ENGINE TODEC (CRANKSHAFT MEASUREMENT fae CENTERLINE cuits ALIGNMENT meraatal vom FIGURE 3-4. ANGULAR ALIGNMENT MEASUREMENT 3-5