1999 Parts Manual 750kw - 1500kw

PARTS CATALOG

750 Kw TO 1500 KwMODEL 1999

RELEASE DATE: 08/03/2000

Jupiter solution GENSET

This parts catalog applies to the standard generator group listed on the cover. Parts illustrations are typical.

Genset Onan name plate:

Model and spec. no.: ______________________________

Serial no.: ______________________________________

Digital control software version: _____________________

Equipment Jupiter name plate:

Serial number: ___________________________________

Plate information:

When reading on plate, gray section means that this is a recommended spare part for thisapplication.

Example: Item 4A & 4B are recommended spare parts

4 163-001-01-B 1 SURGE TANK4A 8AXX-0839 2 SURGE TANK CAP4B 15050298K 1 MURPHY SWITCH5 4 FILLETED ROD 3/8-16UNC x 20" LENGTH

Product Safety Precautions:

Trained, experienced personnel only must perform Service and repair of Jupiter Solution equipment.Improper service or repair may result in properly damage, severe personal injury or death. Do not use thiscatalog as a guide to servicing your equipment. Read and follow the IMPORTANT SAFETYINSTRUCTIONS in the Service manual appropriate for the equipment you are working on.

Contact with USED ENGINE OILS has been identified by the United States federal agency and some USAstate agencies as causing CANCER or REPRODUCTIVE TOXICITY. When checking or changing engineoils take all necessary precautions not to ingest, breathe the fumes or contact the used oils.

Contact with ASBESTOS has been identified by the United States federal agency and some USA statesagencies as causing CANCER or REPRODUCTIVE TOXICITY. When handling engine gaskets take allnecessary precautions not to ingest, or contact the dust from the gaskets. Use adequate ventilation and wearprotective gloves, masks and clothing.

Contact with BENZINE and LEAD, found in gasoline, fuel additives and solvents has been identified bythe United States federal agency and some USA state agencies as causing CANCER or REPRODUCTIVETOXICITY. When checking, draining or adding gasoline and fuel additives or using solvents take allnecessary precautions not to ingest breathe the fumes or contact the liquids. Use adequate ventilation andwear protective gloves, masks and protective clothing.

! WARNING

! WARNING

! WARNING

! WARNING

SUBJECT DESCRIPTION DRAWING

1-Container Container 10D-419-110-2

2-Acoustic Assembly N/A

3-Cooling Assembly 10D419-150-1

4-Fuel System Fuel Tank 10D419-140-1

5-Muffler 750 kw Assembly 10D419-500900 to 1500 kw assembly 10D419-170-3

6-ventillation Assembly 10D419-160-1

7-Genset Assembly Assembly 10D419-170-1

8-Electric Electric

9-Bulletin 10D419-B-0110D419-B-02

10-Retrofit kit 10D419-K01A10D419-K02A10D419-K03A10D419-K04A10D419-K05A10D419-BALANCE LINE

TABLE OF CONTENTS

1-CONTAINER

750 900 1000 1250 1500CPR

1500GE

1 1 1 1 1 1 1 40' CONTAINER2 9001K15 1 1 1 1 1 1 EMERGENCY BREAK GLASS OPERATOR3 1 1 1 1 1 1 REMOTE LADDER4 UNIVERSAL BOOT-8 1 1 1 1 1 1 LOCK PIN BOOT

DESCRIPTION

10D419-11 CONTAINER / DWG: 10D419-110-2 / PLATE: 10D419-100-91

COMMENTTAG PART NUMBER QTY

1/1 BOM 1999 3 pour manuel.xls 8/3/00

2-ACOUSTIC

750 900 1000 1250 1500CPR

1500GE

1 V-99-090 1 1 1 1 1 1 ACOUSTIC PANEL2 V-99-090-1 1 1 1 1 1 1 ACOUSTIC PANEL3 4 4 4 4 4 4 LOUVERS4 2 2 2 2 2 2 ACCESS DOORS5 1 1 1 1 1 1 S5, S6 PANELS6 1 1 1 1 1 1 RAD BIRD SCREEN7 1 1 1 1 1 1 EXHAUST BIRD SCREEN

10D419-12 ACOUSTIC

DESCRIPTION SPECIAL INFORMATIONTAG PART NUMBER QTY


3-COOLING

750 900 1000 1250 1500CPR

1500GE

1 RAD1500KW-R 1 1 RIGHT SIDE RADIATORRAD1250KW-R 1 RIGHT SIDE RADIATORRAD1000KW-R 1 RIGHT SIDE RADIATORRAD900KW-R 1 RIGHT SIDE RADIATORRAD750KW-R 1 RIGHT SIDE RADIATOR

2 RAD1500KW-L 1 1 LEFT SIDE RADIATORRAD1250KW-L 1 LEFT SIDE RADIATORRAD1000KW-L 1 LEFT SIDE RADIATORRAD900KW-L 1 LEFT SIDE RADIATORRAD750KW-L 1 LEFT SIDE RADIATOR

3 E0HT8C045AB 2 2 2 2 2 2 OVERFLOW BOTTLE4 1W04-3000 3 3 3 3 3 3 BLUE HOSE THERMOPOLE 3"

5 1W04-3500 3 3 3 3 3 3 BLUE HOSE THERMOPOLE 3.5"

6 1W04-5000 3 3 3 3 3 3 BLUE HOSE THERMOPOLE 5"

7 CT-400 8 8 8 8 8 8 CLAMP 4"8 CT-350 12 12 12 12 12 12 CLAMP 3.5"9 CT-550L 6 6 6 6 6 6 CLAMP 5.5"

10 YP1 1 1 1 1 1 1 Y PIPE11 RPL-1 1 1 1 1 1 1 PIPE SECTION FORWARD 3"12 RPR-1 1 1 1 1 1 1 PIPE SECTION FORWARD 3"13 CP-5 1 1 1 CENTER SECTION 5"14 CP-2 2 2 2 CENTER SECTION 3"15 FP-5 2 2 2 REAR SECTION 3"16 FP-7 1 1 1 1 REAR SECTION 5"17 UC500 3 3 3 3 3 3 U-BOLT 5"18 FPR-3 1 RIGHT SIDE PIPE 3"19 FPL-4 1 LEFT SIDE PIPE 3"20 CP-1 2 2 2 CENTER PIPE 3"21 CP-4 1 CENTER PIPE 5"22 FPR-1 1 1 RIGHT SIDE PIPE 3"23 FPL-2 1 1 LEFT SIDE PIPE 3"24 FP-6 1 1 CENTER PIPE 5"25 CP-3 1 1 CENTER PIPE 5"

10D419-13 COOLING / DWG: 10D419-150-1 / PLATE: 10D419-100-93



750 900 1000 1250 1500CPR

1500GE

10D419-13 COOLING / DWG: 10D419-150-1 / PLATE: 10D419-100-93


26 10D419-550-001-003 2 2 2 2 2 2 RAD CAP

27 EL-150-K1 1 1 1 1 1 1 LOW LEVEL GAGE


4-FUEL SYSTEM

750 900 1000 1250 1500CPR

1500GE

1 79/1000FGV, 2020PM-OR

1 RACOR FUEL FILTER

2 TANK BAC-RE 1250/1500

1 1 1 FUEL TANK

TANK BAC-RE 750/1000

1 1 1 FUEL TANK

3 361OK47 1 1 1 1 1 1 FUEL GAGE 1 1/2"NPT4 369-01-6008 1 1 1 1 1 EMERGENCY VENT

10D419-14 FUEL / DWG: 10D419-140-1 / PLATE: 10D419-100-94



5-MUFFLER

750 900 1000 1250 1500CPR

1500GE

1 PR-87-99-1500-01-00 1 1 MUFFLER 150099-11245 1 1 MUFFLER 1250, 1000CUSTOM 1 MUFFLER 900PR-87-99-750-01-00 1 MUFFLER 750 LEFTPR-87-99-750-02-00 1 MUFFLER 750 RIGHT

2 PR-87-99-1500-02-00 2 2 FLEX CONNECTOR99-50416 1 1 FLEX CONNECTOR RIGHT SIDE99-50417 1 1 FLEX CONNECTOR LEFT SIDEPR-87-99-750-03-00 1 FLEX CONNECTOR LEFT SIDEPR-87-99-750-04-01 1 FLEX CONNECTOR RIGHT SIDE

3 99-50415 2 2 EXITAC-RC-010-T 2 2 RAIN CAP

4 99-30023 1 1 BRACKET RIGHT SIDE99-30024 1 1 BRACKET LEFT SIDE

5 CUSTOM 1 1 1 1 1 1 SILENCER INSULATION6 PR-87-99-750-05-00 2 ELBOW EXHAUST OUTLET7 AC-RC-08-T 2 RAIN CAP8 PR-87-99-750-12-00 2 SUPPORT

PR-87-99-1500-14-00 1 1 1 1 1 SUPPORT9 PR-87-99-750-13-00 4 MOUNTING BAND

10D419-15 MUFFLER / DWG: 10D419-500 (750Kw) & 10D419-170-3 (900 TO 1500 Kw) / PLATE 10D419-100-95

SPECIAL INFORMATIONDESCRIPTIONTAG PART NUMBER QTY


6-VENTILATION

750 900 1000 1250 1500CPR

1500GE

1 DCP286EK51750480 2 2 2 2 2 2 GENSET FAN2 32-9-4ZR-PAG-40/AS 3 3 3 3 3 3 FAN BLADES ASSEMBLY (RADIATOR)

3 2424211W-99 3 3 3 3 3 3 FAN MOTOR (480V)4 1 1 1 1 1 1 FAN SUPPORT

10D419-16 VENTILATION / DWG: 10D419-160-1 / PLATE: 10D419-100-96



7-GENSET ASSEMBLY

750 900 1000 1250 1500CPR

1500GE

1 1500 DFMB 1 1 GENSET 1500 kW 1250 DFLC 1 GENSET 1250 kW 1000 DFJD 1 GENSET 1000 kW 900 DFHC 1 GENSET 900 kW

750 DFHA 1 GENSET 750 kW 2 2 2 2 2 2 2 SUB SKID PLATES 3 H9075D 12 12 12 12 ENGINE MOUNT

RB42100 10 10 ENGINE MOUNT 4 93192-A 1 1 1 1 1 1 BREATHER BOX 5 AP-1 1 1 AIR FILTER ADAPTER 7" * 10" 6 BR-1110 1 1 CLAMP 7"

10D419-17 GENSET / DWG:10D419-170-1 / PLATE: 10D419-100-97



8-ELECTRIC

TAG PART NUMBER750 900 1000 1250 1500

CPR1500GE

1 2 2 2 2 2 2 BUS DUCT RACKS2 0305-0813-01 1 1 1 1 1 1 BATTERY CHARGER 120V AC, 24 V DC, 10 A

3 908D 2 2 4 4 4 4 BATTERY 12 V DC4 KUP14D15-24 4 4 3 3 3 3 RELAY KUP5 27E893 4 4 3 3 3 3 RELAY KUP BASE6 MK2KP-UA-DC24 1 1 1 1 1 1 LATCH RELAY7 PF113A-E 1 1 1 1 1 1 LATCH RELAY SOCKET8 A19BBC-2C 1 1 1 1 1 1 THERMOSTAT9 2 BATTERY SUPPORT10 1 TRANSFORMATOR SUPPORT11 5412ES723018 1 1 1 1 1 1 MAIN BREAKER BOX12 9007AB21 2 2 2 2 2 2 LIMIT SWITCHSES13 GV2M20 3 3 3 3 3 3 MANUAL STARTER 10HP14 LC1D1810G6 3 3 3 3 3 3 MOTOR STARTER 10 HP15 GV2M10 2 2 2 2 2 2 MANUAL STARTER 3 HP16 LC1D0910G6 2 2 2 2 2 2 MOTOR STARTER 3 HP17 GP3P60-20 1 1 1 1 1 1 DISTRIBUTION PANEL 60A, 240V18 5KVA600120/240 TRANSFORMER 5KVA, 600

5KVA480120/240 TRANSFORMER 5KVA, 48019 5412ES603012 1 1 1 1 1 1 AUXILIARY ELECTRICAL ENCLOSURE

20 HBL1379 4 4 4 4 4 4 SWITCH, 30A, 600V, 3 POLES21 100ARS/2P/24/120V 3 3 3 3 3 3 LAMP, BULB 125 VAC22 50A19/IF24V 3 3 3 3 3 3 LAMP, BULB 24 VDC23 VTCXL11GC 6 6 6 6 6 6 LAMP FIXTURE24 1451W 1 1 1 1 1 1 LIGHT SWITCH 120V 15A25 5320W 1 1 1 1 1 1 DUPLEX PLUG 120V 15A26 FF15M70 2 2 2 2 2 2 MECHANICAL TIMER27 10601 6 6 6 6 6 6 CONNECTOR TECK 9028 62-6490-10464 35 35 35 35 35 35 CONNECTOR TECK STRAIGHT29 FAL34060 1 1 1 1 1 1 AUXILIARY BREAKER 60A30 62-3178-31120 4 4 4 4 4 4 CONNECTOR EMT 3/4 STRAIGHT

31 MAIN BREAKER 120/208, 277/480

SPBSR 316F56 1 1 BREAKER 1600ASPBSR 321F56 1 BREAKER 2000ASPBSR 325F56 1 1 BREAKER 2500A

10D419-18 ELECTRIC /QTY

DESCRIPTION SPECIAL INFORMATION


TAG PART NUMBER750 900 1000 1250 1500

CPR1500GE

10D419-18 ELECTRIC /QTY

DESCRIPTION SPECIAL INFORMATION

SPBSR 330F56 1 BREAKER 3000A

MAIN BREAKER 600VSPBSR 316F56 1 1 1 1 BREAKER 1600ASPBSR 321F56 1 1 BREAKER 2000A


9-BULLETIN

DateJuly 26, 2000Bulletin No. Equipment number10D419-B01 1999 product, 750 to 1500 kWSubjectOverheating, wrong fan rotation

Description:There has been a number of complaints from the field due to engine overheatingon 1999 products. A few units were examined and found to have electricaltroubles, namely :

1. Fan rotation: a few units were found to have one or more fans rotating in thewrong direction. To diagnose this situation, one can measure amperage toeach motor and the motors rotating backwards will draw less current. Thiscondition can also be observed visually.

2. Electrical fan motor overload tripping : some overload relays installed on themotor starting contactors are too sensitive and may cause nuisance tripping.

3. Relay K4 failure: a specific bulletin (10D419-B02) guides on how to modifythe wiring connections to improve the relay life expectancy.

Equipment affected by this bulletin: 1999 product, 750 to 1500 kW.

Correction:1. If one fan rotates in opposite direction than required, remove the power to this

motor, inverse the breaker outlet wiring phase A and B, and reenergize themotor.

2. Verify if the adjustment of the overload relay is at the maximum, and adjust it.If the trouble remains, replace the failed overload relay.

3. See bulletin 10D419-B02

10D419-B02.doc Page 1 of 3

DateJuly 27, 2000Bulletin No. Equipment number10D419-B02 1999 product, 750 to 1500kWSubjectFan latching relay

Description : The fan control latching relay (K4) is wired in a way that therecould be continuously 24VDC to both the latching and the reset coils, causing therelay to get hot and reducing it’s life expectancy.

The goal of this bulletin is to guide through a modification to correct this situation.

Equipment affected by this bulletin : all 1999 Jupiter Solutions products.

Procedure : Each unit will have to be rewired. Ensure that generator set batteryhas been disconnected while doing the work. Consult the following picture to helpidentify the relays to be rewired.

The drawings also included with this bulletin show the wiring schematic as theunits are currently wired and how they should be following the modification.

The thermostat in the radiator section of each container is used to prevent theradiator fans from starting in freezing rain conditions before some heat from theradiators has had a chance to break the ice away. The thermostat can beadjusted to a very cold setting (ex. 40 degrees F) and thus will not have an effecton the operation in moderate climes.


K1 K2 K3 K4 K5

The relays involved in this modification are K1 (run relay) and K4 (fan controllatching relay).

Follow attached drawing for wiring modification.

Some units may not have K5, refer to Cummins Power Rent DiscussionDatabase for updated drawings.


10-RETROFIT KIT

RETROFIT KIT #10D419-K01-A

Function: To install or change the breather box. To remove oil mist and airborne particles comingfrom the engine crankcase breather vent.

Application: 1250KW 1999 JUPITER product

Page listing: 10D419-K01-A 10D419-270-1

Parts required (include in kit):

1-(1) Nelson breather box (93192-A)2-(1) Breather box bracket (870-011-01-B)3-(1) 3/8” oil hose x 10’ length (831-6)4-(4) Clamp for 3/8” hose (HC-6)5-(2) Clamp for 1/2” hose (HC-8)6-(2) Fitting 3/8” hose barb to 1/4 male npt (125HBL-6-4)7-(1) 2 1/4” vent hose x 15’ length8-(1) Clamp for 2 1/4” hose (88HC-32)9-(1) Tubing clamp for 2 1/4” (CL-37)10-(1) Union tee 1/2” female npt (022T-8-8)11-(2) Fitting 1/2” hose barb to 1/2” male npt (125HBL-8-8)12-(1) Fitting 3/8” hose barb to 1/2” male npt (125HBL-6-8)13-(10) Flange bolt 3/8-16unc x 1 1/4” length14-(11) Flange nut 3/8-16unc15-(1) Flange bolt 3/8-16unc x 3/4” length16-(1) Manometer (include with breather box)17-(2) Breather box support (include with breather box)18-(1) Instruction manual (include with breather box)

Tools required for installation:

A-(1) Hand-drillB-(1) Drill 7/16”C-(1) Cutting pliersD-(1) Imperial socket set with ratchetE-(1) 9/16” wrenchF-(1) 7/8” wrenchG-(1) 3/4” wrenchH-(1) Measuring tapeI-(1) SquareJ-(1) MarkerK-(1) Teflon tapeL-(10) Ties


Procedure:

*Note: all fittings must be sealed with Teflon tape

1-Locate the existing breather box, on the same side; you have to drill 6 Dia 7/16” mounting holeson the air filter side support. Refer to drawing for details. Be sure that holes are square and level.

2-Install item 2 on the backside of the mounting holes with item 13,14.

3-Install item 17 on the bracket and mounting holes with item 13,14.

4-Take item 1, place it such that its inlet is at top, unbolt upper and lower drain plug and insertitem 6 in both holes.

5-Mount item 1 on item 17 and close support.

6-Locate existing breather box, unscrew upper clamp that hold flex hose.

7-Take item 10,11,12 and insert them as describe in diagram 11—10—11 | 12

8-Cut existing lower drain hose to insert fitting that have be mounted in procedure 7, and securewith item 5.

9-Take one ends of item 3 connect it with item 12. Cut item 3 as required length to fit connectionto breather box lower drain and make sure that the hose doesn’t make waves to assure oil flow.Secure both ends with item 4.

10-Fix item 16 vertically on air filter side support.

11-Insert the rest of item 3 into breather box upper drain. Cut item 3 as required length to fitconnection to manometer. Secure both ends with item 4.

12-Connect one ends of item 7 on breather box inlet. Cut item 7 as required length to fitconnection to existing breather box upper fitting. Secure both ends with item 8.

*Note: Refer in installation manual to make procedure 13 to 17

13-Connect the rest of item 7 into breather box outlet. Secure with item 8.

14-Cut item 7 as required length to fit application.

15-When the test is correct, mark the appropriate height of the hose. Drill 1 Dia 7/16” hole 2”lower than the mark.


Procedure:

16-Install item 9 into the hole with item 14,15. Before tightening, pass item 7 into item 9 to reachthe top hose mark. Tight the tubing clamp.

17-Secure all hoses with ties to avoid hoses to move or be in contact with hot components of theGenset.






1-(1) Nelson breather box (93194-A)2-(1) Breather box bracket (870-011-01-B)3-(1) 3/8” oil hose x 8’ length (831-6)4-(4) Clamp for 3/8” hose (HC-6)5-(1) Flange bolt 3/8-16unc x 3/4” length6-(2) Clamp for 3/4” hose (88HC-12)7-(1) 1 3/4” vent hose x 12’ length8-(3) Clamp for 1 3/4” hose (88HC-20)9-(1) Tubing clamp for 1 3/4” hose (CL-29)10-(1) Union tee 3/4” female npt (022T-12-12)11-(2) Fitting 3/4” hose barb to 3/4” male npt (125HBL-12-12)12-(1) Reducer bushing 3/4” male npt to 1/4” female npt (0102-12-4)13-(3) Fitting 3/8” hose barb to 1/4” male npt (125HBL-4-6)14-(10) Flange bolt 3/8-16unc x 1 1/4” length15-(11) Flange nut 3/8-16unc16-(1) Manometer (include with breather box)17-(2) Breather box support (include with breather box)18-(1) Instruction manual (include with breather box)


A-(1) Hand-drillB-(1) Drill 7/16”C-(1) Cutting pliersD-(1) Imperial socket set with ratchetE-(1) 9/16” wrenchF-(1) 1 5/16” wrenchG-(1) 3/4” wrenchH-(1) Measuring tapeI-(1) SquareJ-(1) MarkerK-(1) Teflon tapeL-(10) Ties


Procedure:


1-Locate the existing breather box without the oil filler, on the same side; you have to drill 6 Dia7/16” mounting holes on the air filter side support. Refer to drawing for details. Be sure thatholes are square and level.

2-Install item 2 on the backside of the mounting holes with item 14, 15.

3-Install item 17 on the bracket and mounting holes with item 14, 15.

4-Mount item 1 on item 17, place it such that its inlet is at top and close support. Unbolt upper andlower drain plug and insert item 13 in both holes.


6-Take item 10,11,12,13 and insert them as describe in diagram 11—10—11 | 12

| 13








Procedure:




15-Install item 9 into the hole with item 5, 15. Before tightening, pass item 7 into item 9 to reachthe top hose mark. Tight the tubing clamp.







1-(1) Nelson breather box (93194-A)2-(1) Breather box bracket (870-018-01-B)3-(1) 3/8” oil hose x 8’ length (831-6)4-(4) Clamp for 3/8” hose (HC-6)5-(1) 3/4” oil hose x 6’ length (831-12)6-(6) Clamp for 3/4“ hose (88HC-12)7-(1) 1 3/4” vent hose x 12’ length8-(3) Clamp for 1 3/4” hose (88HC-20)9-(1) Tubing clamp for 1 3/4” (CL-29)10-(3) Union tees 3/4” female npt (022T-12-12)11-(4) Fitting 3/4” hose barb to 3/4” male npt (125HBL-12-12)12-(1) Conversion adapter m33 male to 1-11 1/2” female npt (M33x2.0-1 FO80HG-S)13-(2) Fitting 3/8” hose barb to 1/4” male npt (125HBL-4-6)14-(1) Reducer bushing 1-11 1/2” male npt to 3/4” female npt (0102-16-12)15-(1) Fitting 3/8” hose barb to 3/8” male npt (125HBL-6-6)16-(1) Reducer bushing 3/4” male npt to 3/8” female npt (0102-12-6)17-(11) Flange bolt 3/8-16unc X 1 1/4” length18-(11) Flange nut 3/8-16unc19-(1) Manometer (include with breather box)20-(2) Breather box support (includes with breather box)21-(2) Nipple 3/4” male npt to 3/4” male npt (0101-12-12)22-(1) Hose id 1 1/4” OD 1 3/4” x 2” length23-(1) Reducing adapter 1x11 1/2” female npt to 3/4” male npt (0201-16-12)24-(1) Fitting 1 1/4” hose barb to 1x11 1/2” male npt (0188-16-20)25-(1) Instruction manual (include with breather box)


A-(1) Hand-drill B-(1) Drill 7/16”C-(1) Cutting pliers D-(1) Imperial socket set with ratchetE-(1) 9/16” wrench F-(1) 3/4” wrenchG-(1) 1 5/16” wrench H-(1) Measuring tapeI-(1) Square J-(1) MarkerK-(1) Teflon tape L-(10) TiesM-(1) 1 9/16” wrench


Procedure:

*Note: All fittings must be sealed with Teflon tape To be done when doing oil change

1-Drill 6 Dia 7/16” mounting holes on the right side air filter support. Refer to drawing fordetails. Be sure that holes are square and level.





6-Take item 12,14,11 and assemble them as describe in diagram 12—14—11

7-Refering to drawing, locate oil pan, remove the plug and install procedure 6 kit.

8-In the front of the engine, locate the 2 hoses (one each side) that come from engine breather box.Remove the existing hose that is connected on the metal tube, both sides.

9-Measure approximately the length you need to fit connection from right side metal tube to theitem 11 in the oil pan. Cut item 5 as required length. Connect it from the right side metal tube toitem 11 in oil pan and secure it with item 6.

10-Take the rest of item 5 connect it to the left side metal tube and secure it with item 6.

11-Take item 10,11,15,16,21 and insert them as describe in diagram 21—10—11 | 16 | 15

12- Take item 10,21,23,24 and insert them as describe in diagram 21—10— | 23 | 24


Procedure:

13- Take item 10,11x2 and insert them as describe in diagram 11—10— | 11

14-Take kit that have been assemble in procedure 11,12,13, connect them as followed(P13—P12—P11). When connecting together, P13 must be positioned 90 degree clockwise

P13 P12 P11

15-Refering to procedure 9, cut that hose to be able to connect the kit that you made in procedure

14. Before cutting, be sure that the connection with the left side hose will have a down slope toassure oil flow. When connecting, P13 must be higher than P11. The right side hose have to beconnected with both extremity of the kit and the left side hose to the P13 side fitting. Cut hoses tofit connections. Secure all connections with item 6.


17-Take item 3, insert one end in breather box lower drain. Cut item 3 as required length to fitconnection to P11 fitting and make sure that the hose doesn’t make waves to assure oil flow.Secure both ends with item 4.

18-Take the rest of item 3, insert one end in breather box upper drain. Cut item 3 as requiredlength to fit connection with item 19. Secure both ends with item 4.

19-Insert item 22 in P12 fitting.

20-Connect one end of item 7 in breather box inlet. Cut item 7 as required length to fit connectionto P12. Secure both ends with item 8.

*Note: Refer in Nelson breather box installation manual to make procedure 21 to 25





Procedure:








1-(1) Nelson breather box (93194-A)2-(1) Breather box bracket (870-018-01-B)3-(1) 3/8” oil hose x 8’ length (831-6)4-(4) Clamp for 3/8” hose (HC-6)5-(1) 3/4” oil hose x 6’ length (831-12)6-(6) Clamp for 3/4“ hose (88HC-12)7-(1) 1 3/4” vent hose x 12’ length8-(3) Clamp for 1 3/4” hose (88HC-20)9-(1) Tubing clamp for 1 3/4” (CL-29)10-(3) Union tees 3/4” female npt (022T-12-12)11-(4) Fitting 3/4” hose barb to 3/4” male npt (125HBL-12-12)12-(1) Conversion adapter m33 male to 1-11 1/2” female npt (M33x2.0-1 FO80HG-S)13-(2) Fitting 3/8” hose barb to 1/4” male npt (125HBL-4-6)14-(1) Reducer bushing 1-11 1/2” male npt to 3/4” female npt (0102-16-12)15-(1) Fitting 3/8” hose barb to 3/8” male npt (125HBL-6-6)16-(1) Reducer bushing 3/4” male npt to 3/8” female npt (0102-12-6)17-(11) Flange bolt 3/8-16unc X 1 1/4” length18-(11) Flange nut 3/8-16unc19-(1) Manometer (include with breather box)20-(2) Breather box support (includes with breather box)21-(2) Nipple 3/4” male npt to 3/4” male npt (0101-12-12)22-(1) Hose id 1 1/4” OD 1 3/4” x 2” length23-(1) Reducing adapter 1x11 1/2” female npt to 3/4” male npt (0201-16-12)24-(1) Fitting 1 1/4” hose barb to 1x11 1/2” male npt (0188-16-20)25-(1) Instruction manual (include with breather box)


A-(1) Hand-drill B-(1) Drill 7/16”C-(1) Cutting pliers D-(1) Imperial socket set with ratchetE-(1) 9/16” wrench F-(1) 3/4” wrenchG-(1) 1 5/16” wrench H-(1) Measuring tapeI-(1) Square J-(1) MarkerK-(1) Teflon tape L-(10) TiesM-(1) 1 9/16” wrench


Procedure:

*Note: All fittings must be sealed with Teflon tape To be done when doing oil change

1-Drill 6 Dia 7/16” mounting holes on the right side air filter support. Refer to drawing fordetails. Be sure that holes are square and level.





6-Take item 12,14,11 and assemble them as describe in diagram 12—14—11

7-Refering to drawing, locate oil pan, remove the plug and install procedure 6 kit.

8-In the front of the engine, locate the 2 hoses (one each side) that come from engine breather box.Remove the existing hose that is connected on the metal tube, both sides.

9-Measure approximately the length you need to fit connection from right side metal tube to theitem 11 in the oil pan. Cut item 5 as required length. Connect it from the right side metal tube toitem 11 in oil pan and secure it with item 6.

10-Take the rest of item 5 connect it to the left side metal tube and secure it with item 6.

11-Take item 10,11,15,16,21 and insert them as describe in diagram 21—10—11 | 16 | 15

12- Take item 10,21,23,24 and insert them as describe in diagram 21—10— | 23 | 24


Procedure:

13- Take item 10,11x2 and insert them as describe in diagram 11—10— | 11

14-Take kit that have been assemble in procedure 11,12,13, connect them as followed(P13—P12—P11). When connecting together, P13 must be positioned 90 degree clockwise

P13 P12 P11

15-Refering to procedure 9, cut that hose to be able to connect the kit that you made in procedure

14. Before cutting, be sure that the connection with the left side hose will have a down slope toassure oil flow. When connecting, P13 must be higher than P11. The right side hose have to beconnected with both extremity of the kit and the left side hose to the P13 side fitting. Cut hoses tofit connections. Secure all connections with item 6.


17-Take item 3, insert one end in breather box lower drain. Cut item 3 as required length to fitconnection to P11 fitting and make sure that the hose doesn’t make waves to assure oil flow.Secure both ends with item 4.

18-Take the rest of item 3, insert one end in breather box upper drain. Cut item 3 as requiredlength to fit connection with item 19. Secure both ends with item 4.

19-Insert item 22 in P12 fitting.

20-Connect one end of item 7 in breather box inlet. Cut item 7 as required length to fit connectionto P12. Secure both ends with item 8.

*Note: Refer in Nelson breather box installation manual to make procedure 21 to 25





Procedure:








1-(1) Nelson breather box (93192-A)2-(1) Breather box bracket (870-011-01-B)3-(1) 3/8” oil hose x 10’ length (831-6)4-(4) Clamp for 3/8” hose (HC-6)5-(2) Clamp for 1/2” hose (HC-8)6-(2) Fitting 3/8” hose barb to 1/4 male npt (125HBL-6-4)7-(1) 2 1/4” vent hose x 15’ length8-(1) Clamp for 2 1/4” hose (88HC-32)9-(1) Tubing clamp for 2 1/4” (CL-37)10-(1) Union tee 1/2” female npt (022T-8-8)11-(2) Fitting 1/2” hose barb to 1/2” male npt (125HBL-8-8)12-(1) Fitting 3/8” hose barb to 1/2” male npt (125HBL-6-8)13-(10) Flange bolt 3/8-16unc x 1 1/4” length14-(11) Flange nut 3/8-16unc15-(1) Flange bolt 3/8-16unc x 3/4” length16-(1) Manometer (include with breather box)17-(2) Breather box support (includes with breather box)18-(1) Instruction manual (include with breather box)


A-(1) Hand-drillB-(1) Drill 7/16”C-(1) Cutting pliersD-(1) Imperial socket set with ratchetE-(1) 9/16” wrenchF-(1) 7/8” wrenchG-(1) 3/4” wrenchH-(1) Measuring tapeI-(1) SquareJ-(1) MarkerK-(1) Teflon tapeL-(10) Ties


Procedure:


1-Locate the existing breather box, on the same side; you have to drill 6 Dia 7/16” mounting holeson the air filter side support. Refer to drawing for details. Be sure that holes are square and level.






7-Take item 10,11,12 and insert them as describe in diagram 11—10—11 | 12











Procedure:



ENG-007

Installation of overflow bottles on 1500 Kw for GE

Materials

• 1 box of right kit• 1 box of left kit

Procedure

1. Make 2 holes of ¼ `` in the left rad see drawing # 10D419-150-1 for position ofholes

2. Install the left kit3. Plug the hose in the cap on the top of the rad4. See pics of left rad

5. Make 2 holes of ¼ `` in the right rad see drawing # 10D419-150-1 for position ofholes

6. Install the right kit7. Plug the hose in the cap on the top of the rad8. See pics of right rad

LEFT RADIATOR

RIGHT RADIATOR

BOTH RADIATORS

F:\002-Produits\Jupiter 10D419\radiator retrofit.doc

INTER CONNECTION BETWEEN THE 2 RADIATORS1999 PROJECT

Required material

1 - ½" dia. Radiator hose push lock

2 – 2 fitting ½ "dia. pipe. Thread push lock and swivel

3 – 7 clips CL17

4 – 7 nuts 3/8" lock nuts

5 - 7 flat washer 3/8" lock

6 – Pipe sealant

Tools

1 - 3/8" dia. ratchet c/w socket 9/16" dia.

2 – Exacto

3 – Wescott 12"

RIGHT RADIATORCLIPS CONNECTION

LEFT RADIATOR MATERIAL AND TOOLS

F:\002-Produits\Jupiter 10D419\radiator retrofit.doc

INTER CONNECTION BETWEEN THE 2 RADIATORS1999 PROJECTPROCEDURE

1 – Remove the ½" dia. Pipe thread plugs from each radiator right hand and left hand

2 – Place the fitting ½ "dia pipe. Thread push lock and swivel on each radiator Right hand and left hand

3 – Install the CL 17 clips on the retention bolts of the ceiling radiator fan. The clips are installed 2 on each side and 3 on the face.

4 – Without removing the 3/8" bolts, add the clip, the flat washer and the lock nut to the bolt do not loosen the bolts.

5 – Insert the radiator hose in to the radiator fitting Right hand and left hand

6 – Insert the hose in to the clips

7– Tighten all the nuts on to the clips.

REPORT VISIT ATLANTAGE RENTAL UNITS

Subject : GE Rentals

Onan Corporation was tasked to provide technical assistance in Atlanta to CumminsSouth and 22 GEER personnel, in order to resolve operating problems with the GePower Rental Units. 25 of the 1999 models and 5 of the 2000 models are presently inoperation in Georgia, these units have been rented by Georgia Power and are beingutilized for Peak Shaving in parallel with the utility.

Inspection of the units at the sites

An inspection of the units showed the following problems:

- Two of the units had one rad fan motor rotating in the wrong direction. This was corrected by inverting phase rotation at the motor connections.

- One of the units had one of the rad fan not operating, due to the overload device failure. This was corrected by replacing the defective device.

Wiring problems

The control wiring routing from the main breaker enclosure or the auxiliary enclosure tothe accessory box (A40) of the generator, have been subjected to breakage and arealso causing failure of the base of relay K4 and K5. This type of failure has been theprimary cause of rad fan control and generator breaker control failures. The type ofconductor used is too stiff and if not restricted in it's movement; breakage of theconductor strands will occur or damage to the internal connection on the relay base.

In order to correct this situation, all electrical connections in the A40 were verifiedand the latter conductors, limited in their movement by securely fastening them with tiewraps.

Relay K5

A K5 relay was wired in, on all of the early production units, that were lacking the relay.

Relay K4

Relay K4 was subjected to abnormal amount of heat that was generated by having bothof it's coils energized simultaneously for prolonged periods of time. This situation wascorrected by rewiring the relay, to permit only one coil to be energized and bymaintaining that signal for only a short duration.

Rad room thermostat

One of the units had a defective thermostat. The NO contact on that unit was shorted toenable operation until a replacement as been found.

List of units inspected and work performed

HRS UNIT# GEN.SERIAL#

PRESENTSITELOCATION

WORK PERFORMED

125 1346 I990978672 Douglasville Check control wiring and did K4mod.

115 1376 I990993017 Douglasville Check control wiring and did K4mod.The K4 relay is defective therad fan contactor are presently fedby the signal of the cooling fanswhile awaiting a replacementrelay.

122 1381 I990993018 Douglasville Check control wiring and did K4mod. Repaired broken conductoron relay K5, term.#7 Breakercontrol AC.

116 1380 I990993019 Grover's Lake Check control wiring and did K4mod. Repaired broken conductoron relay K5, term.#7 Breakercontrol AC. Secured looseconnections on TB3-1.

119 1348 I990993014 Grover's Lake Check control wiring and did K4mod.

76.8 1378 I990993304 Grover's Lake Check control wiring and did K4mod. Changed relay base K5.Broken pin on term. #7. The relayin the K4 socket wasn't the properone install correct one. The coil ofthe K4 installed as been subject toheat, it is operational but should

be changed.

278 1104 E990912663 Russell-#38 Check control wiring and did K4mod. Rewired to install K5.

181 1123 F990937249 Russell-#38 Check control wiring and did K4mod. Rewired to install K5.Rewired all of the relays in the A40of this unit as the wiring on thisunit was not similar to the others.

142 1113 F990926419 Hwy 96 -Sub# 16

Check control wiring and did K4mod. Rewired to install K5. Brokenbase of K4 (3 pins). This unit wasoverheating, changed rotation ofrad fan #3.

137 1212 G990953249

Hwy 96 -Sub# 16

Check control wiring and did K4mod. Rewired to install K5.Defective thermostat, shorted NOcontact.

134 1347 I990993015 West 14 Check control wiring and did K4mod.

147 1385 I990993307 West 14 Check control wiring and did K4mod.This unit was overheating,changed rotation of rad fan #3.

134 1205 G990953251

West 14 Check control wiring and did K4mod.Rewired to install K5.

130 1345 I990993016 Bonaire -Sub#36

Check control wiring and did K4mod. This unit was overheatingRad fan motor #1 notfunctionnning , replaced OLprotection device. Replaced 3securing mounting bracket boltson left side of silencer.

132 1437 J990000189 Bonaire -Sub#36

Check control wiring and did K4mod.

2363 A000049089 Pancras This unit is one of the first 5 unit ofthe 2000 model, did mod on standtube in expansion tank.

C00007116 This unit is one of the first 5 unit of

2365 8 Pancras the 2000 model, did mod on standtube in expansion tank.

23.7 2364 A000049090 GE Shop This unit is one of the first 5 unit ofthe 2000 model, did mod on standtube in expansion tank. This unitas had a clutch failure.Replacement had arrived whenready to depart from Atlanta . Thedefective clutch will be sent backto Jupiter by Cummins South forexpertise. The personnel at GEERstated that this unit, on arrival fromJupiter, did not have any coolantfluids.

Comments and suggestions collected from the 22 GEER .

- The actuated roof door on one of the unit does not close totaly, 4" gap, is there anyajustment?- Weather stripping on door opening installed on backwards, GEER personnalcorrected the problem.- No connexion on TB1-59. GEER had to locate wire.- Complaints about the Age of the trailers ! They were sourced by GE.- It was suggested that a cover should be added between the door ledge of the radroom and the fuel tank.- The ceiling insulations material moves forward during transport and should besecured.

General comments from the undersigned

- Not all of the units were attended to for the following reasons:- The units were not located in a close vicinity;- A representative from the present user was required for access to the sites;and- The access time to the units was restricted to, when the unit were not called upon to operate.

- The Field Service Technician Tom Dutton ( Cummins South), was the main technicianinvolve in the repairs and modifications performed during this visit, consequently he isdefinetely the person to seek for further assistance regarding these units.- Original schedule for my departing from Atlanta was postponed , since it was

requested that we deliver to 22GEER, informal training on the 2000 models.

Roy. Michel E.G.S. Tech.Onan Est du Canada

Documents

1999 Parts Manual 750kw - 1500kw