Standard Repair Times SRT Family: CS Portable Generator Sets EGMBA EGMBB EGMBC EGMBD EGMBE EGMBG EGMBR EGMBS EGMBT EGMBU English 8-2008 900−0636 (Issue 1)
Table of Contents Contents Page Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv Types of Standard Repair Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Administrative SRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Contents Page Group 13 − Electrical Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 17 Group 14 − Engine or Generator Set Testing . . . . . . . . . . . . . . . . . . . . . . . . .
Foreword The Standard Repair Times (SRT) in this manual represent the time required to perform service repairs on Onan Engine and Generator Sets. These times are representative of an average mechanic in a typical dealer or distributorship using the prescribed hand tools, equipment, and all available service tools and equipment required to perform quality repairs and do all necessary testing.
General Information Standard Repair Times (SRT) are lists of work tasks (procedures) and the time required to perform those tasks. The procedures list the work tasks required to be sure an engine or generator set is ready to return to service at the lowest possible cost to the customer.
Troubleshooting SRT Troubleshooting SRT are found only in Group 00 − Complete Engine. These SRT are intended to be used when diagnosing and analyzing engine, generator set or component failures. Troubleshooting SRT are broken down in to logical numbered steps. The time for each step is cumulative with successive steps, including the time for the appropriate preceding step(s). Some troubleshooting SRT contain time to remove and install components to perform the check(s) listed. Most do not.
SRT Coding System Each SRT has a unique code so that SRT data can be computerized. The numbering system used is common to all the SRT manuals for all Onan engines and generator sets. The portion of the system shown in the manual contains three segments: • Group Number • Procedure Number • Step Number Group Numbers Group numbers (the first two digits in the SRT code) are used to identify major engine components. The sample list below explains the group numbers used in SRT charts.
Group Number Specific Repair Number Contents of Group 16 Mounting Adaptations 17 Miscellaneous 21 Generator Equipment 22 Hardware 25 Generator Components 26 Generator Control Components 27 Transfer Switches 99 SRCT 9XX Description of Category (SRCT in Group 99) General/Miscellaneous Step Numbers While all SRT codes will contain a Group and Procedure number, only those procedures that are broken down into steps have step numbers. The step numbers are sequential within a SRT.
− How difficult it is for the mechanic to reach the engine or generator set even after the interfering application hardware has been removed. While the most frequent use of SRT information is the Onan Warranty System, it is Onan’s intent that the SRT be applicable to repairs conducted for any customer. As SRT’s are developed, it is assumed: − That all the required tools, equipment, and supplies are available in sufficient quantity and in operating condition.
Time Allowances After the total productive time is established, an additional allowance of 15 percent is added to cover the following: − Personal time of 5 percent for: − Scheduled rest breaks − Personal phone calls − Restroom breaks − Shift changes − Supplementary time of 10 percent to cover normal work interruptions: − Seized or hard turning fasteners − Extra time for extremely dirty equipment − Excessive waiting time for replacement parts − Brief assistance to other mechanics (less than 5 minutes) − Rout
Non-Productive Work Analysis of past SRT time studies reveals the following general types of work that were not considered to be productive: − Waiting on camshaft gears to heat and cool − Waiting on another mechanic to finish using special tools or shop equipment − Hunting for misplaced parts − Repairing shop equipment − Sorting through capscrews, to find the correct length, that were all thrown together into one basket during disassembly − Repairing customer supplied components − Salvaging parts or tools t
“A” Accessibility Rating 1. Engine or generator sets mounted in equipment where 90 percent of the work can be performed while standing on the ground, shop floor, or flat work deck. 2. Engine or generator set can be accessed without removing any doors or panels. 3. Interfering application hardware can all be removed. 4. Clearance is sufficient for hands, wrenches, and drain and fill operations, making visual checks and room to stand and work. “B” Accessibility Rating 1.
It is intended that other appropriate SRT can be used to supplement a SRCT as long as the work does not overlap. If there is overlapping work, do not use a SRCT. How To Use This Manual 1. Determine the actual work performed: − Obtain this information from the work description on the repair order. 2. Determine the Accessibility Code: − Determine the application from the repair order.
− Repeat the steps in this paragraph until you have determined a SRT for all the work performed. 5. Determine the appropriate troubleshooting SRT: − Read the repair order to determine what troubleshooting work was performed. − Find the contents page for Group 00. − Read the contents page for procedure to determine the work included in each step. − If the work performed and the work included in the troubleshooting SRT are the same, all or in part, determine and record the time of the SRT step.
Standard Repair Times Review Procedure Onan Corporation makes every effort to be sure the SRT published in this manual are credible and equitable.
Group 00 − Complete Engine Contents Page TROUBLESHOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ENGINE CRANKS BUT WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE DIFFICULT TO START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 2
00−021 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.3 − − − − − 0.3 − − − − − 0.
00−031 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.3 − − − − − 0.3 − − − − − 0.3 − − − − − 0.
00−044 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.3 − − − − − 0.2 − − − − − 0.
In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.5 − − − − − 0.5 − − − − − 0.
In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.4 − − − − − 0.5 − − − − − 0.6 − − − − − 0.
00−0DJ In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.4 − − − − − 2.0 − − − − − 0.3 − − − − − 0.
00−901 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S 0.4 − − − − − − − 0.7 − − − − − 0.1 − − − − − 0.
13−109 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.1 − − − − − 0.
Group 11 − Exhaust System Contents Page EXHAUST PIPE/TUBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 12
11−3AB Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A B EXHAUST PIPE/TUBE − REPLACE Step 1 Includes: 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 14 B C D Special S
Group 13 − Electrical Equipment Contents Page STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVE AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 BATTERY CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 16
13−104 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.5 − − − − − 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 18 B C D Special S
Group 14 − Engine or Generator Set Testing Contents Page TEST RUN GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 20
14−704 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 22 B C D Special S
Group 16 − Mounting Adaptations Contents Page FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 REMOVE AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 24
16−1AI In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 26 B C D Special S
Group 17 − Miscellaneous Contents Page MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVE AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 VIBRATION ISOLATORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 28
17−131 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.3 − − − − − 0.5 − − − − − 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 30 B C D Special S
Group 21 − Generator Equipment Contents Page MAIN CIRCUIT BREAKER (AC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 REPLACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 OIL PRESSURE SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 32
21−102 In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 0.3 − − − − − 3.0 − − − − − 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 34 B C D Special S
Group 25 − Generator Components Contents Page MAIN ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVE AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 MAIN STATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 36
In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 1.5 − − − − − 1.5 − − − − − 0.5 − − − − − 1.
In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 1.
Group 26 − Generator Control Components Contents Page DC WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 REMOVE AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
This Page Intentionally Left Blank 40
In-Chassis Service Accessibility Codes Standard Repair Times Removed From Chassis Procedure Number and Description R A B C D Special S − − 1.1 − − − − − 0.
Standard Repair Times Removed From Chassis Procedure Number and Description R In-Chassis Service Accessibility Codes A This Page Intentionally Left Blank 42 B C D Special S
Index O A Administrative Time, Open/Close Repair Order (Shop), 9 Oil, Drain/Fill, 9 Air Cleaner Assembly, Remove and Install, 9 Oil Pressure Sender, Replace, 33 Air Cleaner Element, Replace, 10 Output Lead Terminal Block, Replace, 37 B S Battery, Replace, 29 Spark Plug, Change, 10 Battery Cable, Replace, 17 Starter Motor, Removal and Install, 17 T D DC Wire Harness, Remove and Install, 41 Tank Level Gauge, Replace, 33 Display Panel, Remove and Replace, 41 Test Rotor Windings, 8 Stator Windi
This Page Intentionally Left Blank 44
Request for SRT Review Distributor/Dealer Data Phone No. Distributor/Dealer Address State City Zip Code Country My experience has indicated the following repair procedures require more time: Procedure Data SRT Number Procedure Discription Published time Hrs.
Cummins Power Generation 1400 73rd Ave. NE Minneapolis, MN 55432 USA Phone 1 763 574 5000 Toll-free 1 800 888 6626 Fax 1 763 574 5298 Email www.cumminsonan.com/contact www.cumminsonan.com CumminsR, OnanR, the “C” logo, and “Performance you rely on.” are trademarks of Cummins Inc. E2007 Cummins Power Generation, Inc. All rights reserved.
