CK5
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'83...? ONAN diesel genset startup project.

I know absolutely nothing about electrical. So I’m just going to follow along here and watch.

That will be the best thing ever for you to get running and working! Up the value of your place significantly I would suspect too!

None of the guys on smokstak have ever really seen a generator like mine, in terms of the control box not being there and the application is a strange one. I have found out that the gen set is the " king of the j series " onan generators. Continous 15 kw with all the options, a very sought after unit for homes due to it being single phase 120/240.

So far ive done :
- Fuel filters
- Setiment bowl and screen
-Oil filter
- Cleaned the thermostat and made a gasket
- Set the point gap on the centrifugal switch to .020
- Marked all the outgoing connections i need to wire up a control box
- scrubbed the thing a few times now.

Next on the list is :

- Set/Check valve lash
- Order air cleaner since mine vanished on first touch
-Clean / Check crankcase breathers.
-ect...


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Got the valve lash all set. Intakes were pretty close and the exhaust valves were a bit tight... Hmm I would think they should be a bigger gap and not lack of... But who knows. Maybe the break in period would cause this, things heating up and shrinking for the first time? Either way! Moving on..


Got the thermostat pulled and cleaned. It's a 150 degree and seems to be okay, I was going to boil it and check buuuutt... Meh..


Pulled the fuel tank out of the canister also. Got it propped up and drained. No water which is great but the fuels definitely pretty varnished.. assuming it's been in there since about 1984... Last time the fire extinguisher was inspected...
It's got an awesome brass fuel tank cap. Filled the bottom of the tank with parts cleaner and let it sit for about 3-5 days. Rinsed out and filled with clear fresh diesel. Also tossed a random filter on, that I had laying around to catch any junk that didn't drain out.

An amazing gentleman over on smokstak sent me the guts of his control box for a similar gen set so tackling the box of wires, relays and contactors.. he also sent me the voltage regulator circuit board so I don't have to buy a new aftermarket one and make it work.

Radiator seems to be holding water but has a definite crack at the top. Hoping to just seal that up for now, it was super cruddy but I think I got some of that crap out for now.

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Got it sorta rigged up for now. Going to finish bleeding tomorrow and try to fire it up! When she runs I'll start working on a control box. I have this sheet of steel to make a something something out of.

Turns out intake manifold glow plugs work...
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Hopefully you are building a control panel that permanently houses those gauges!

Martin
 
Due to a small wiring mix up I fried the temp gauge by cracking the ceramic resistor on the back.. but yes I'm keeping the Chevy oil gauge!
 
You've come a long way Nick...this level of electrical would have had you running for the hills only a few years ago!
 
You've come a long way Nick...this level of electrical would have had you running for the hills only a few years ago!
I just learned to read the wiring diagrams.. did it really take that long!? :rotfl: .

Having my own space for the last two years really has enabled me to get my fingers on more stuff, and have the space to set stuff on fire, say whoops a lot and tinker on stuff... If it doesnt work out, i can open the door and toss it out... Its also a dream to have a space like this. Sounds cliche, but i honestly never thought in my whole life id have something like this, aint going to waste.,:saweet:
 
Well ..... nothing says "Ey, finish that crap ya started ", Like a couple ft of snow overnight, no power , and a pipe bursting since it hasnt been - 12 here since i moved here at least, and dont think its a common thing. Anyway, just lifes way of kicking ya in the butt. I had finally made some space for the gen set infront of the c10 and its much nicer to work on now. Things i need to get done:

- Clean up wiring, and install / Fab control box:

Going to buy a thin sheet of stainless since this is will be outdoors, and try out my little bench brake i got. Unless i can find a big empty utility box for sale.. seems like its easier to just make it. I do plan on having some shelter above this machine but our winters are still very wet regardless. Ive ordered a set of typical sealed gauges, a AC voltage LCD panel display, and the classic harbour freight "RACE USE ONLY" -push start switch panel. Id love to keep the chevy gauges but they wont hold up too well in the elements outdoors.

After messing around with this giant HC of a wire loom and having no wire to wire in my switch panel, i decided to put the effort into removing the whole extension harness at both ends. This removed much clutter as its also not needed for this application, since there is no remote control panel like the previous set up and It also gave me a bunch of nice wiring i can use to wire in my control box. Im going to mount it on the rear where the factory one would sit. Going to wire wheel the little factory control box and start re-assembling and routing wires when the gauges come in the mail.

- Wire in voltage regulator:

Managed to find the drawings for the voltage regulator, and lucky enough it matches the used one i got. It seems to have also been set up for 60 HZ, single phase 110 AC. Theres a jumper to be removed if using a rheostat or some other stuff, but seems pretty good to go. I will mount it in the control box also.

- Wiring into the house:

Im thinking of putting a fuse and plug receptacle on the generator. A 50 amp plug for the transfer switch that i will install in the house and 2 GFI outlets ( 4 plugs ) for accesories back there or whatever.

- Housing and transportation:


ive decided to build some sort of frame for this thing, most likely out of 1x2 box steel or maybe 2x2 square tubing. I can use this to mount the fuel tank, support the exhaust tubing and muffler, support the front radiator assembly and shroud. This way its a portable unit, and it also makes it so i can hoist it from the frame and not the motor itself when i toss it over the shop into the backyard again.






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I do have a suggestion:
Unless the genset already has one, some do, pick up a frequency readout. I have one for my big genset. Not sure where I got it, next time I am in the barn I will try to get the make and model.
I never wired it into the set, just put two solid conductor wires on it and laid it in the big transfer switch box.
There are no switches or settings, you just hook the two screw terminals to 240V, and it lights up with the frequency. Every so often I pick it up and touch the ends of the two wires to the connections of the transfer contactor and make sure I'm getting 60 cycle.

I have noticed that when it first starts up, its running about 58.5 or so, but after it warms up a couple of minutes it stabilizes at 60.
I can tweak the governor a little if I have to, but once I got it set to start with, its held up just fine.
For the most part, nothing in the house will mind a couple of cycles per second more or less. Any induction motors will run slightly faster or slower, and so will any line voltage clocks.
But its better to be correct.
 

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