Standard Repair Times

1 SRT Family: CSStandard Repair TimesPortable Generator SetsEGMBAEGMBBEGMBCEGMBDEGMBEEGMBGEGMBRE GMBSEGMBTEGMBUE nglish8-2008900 0636 (Issue 1) i Table of ContentsContentsPageForewordiii.. General Informationiv.. Types of Standard Repair Timesiv.. Administrative SRTiv.. Troubleshooting SRTv.. Repair SRTv.. Standard Repair Combined Timesv.. SRT Coding Systemvi.. Group Numbersvi.. Procedure Numbersvi.. Step Numbersvii.. Manual Organizationvii.. Cummins/Onan SRT Objectives and Philosophyvii.. How Standard Repair Times are Developedviii.. Productive Repair Timeviii.. time Allowancesix.. Work Not Included in an SRTix.. Non-Productive Workx.. Service Accessibility Codesx.. A Accessibility Ratingxi.. B Accessibility Ratingxi.. C Accessibility Ratingxi.. D Accessibility Ratingxi.. Standard Repair Combined Times (SRCT)xi.. How To Use This Manualxii.. Standard Repair Times Review Procedurexiv.. Company Actionxiv.. Group 00 Complete Engine1.

2 TROUBLESHOOT3.. ENGINE8.. TEST8.. ADMINISTRATIVE TIME9.. FAN9.. AIR CLEANER ASSEMBLY9.. OIL9.. SPARK PLUG10.. AIR CLEANER ELEMENT10.. Group 11 Exhaust System11.. EXHAUST PIPE/TUBE13.. ii ContentsPageGroup 13 Electrical Equipment15.. STARTER MOTOR17.. BATTERY CABLE17.. Group 14 Engine or Generator Set Testing19.. TEST RUN GENERATOR21.. Group 16 Mounting Adaptations23.. FUEL TANK25.. Group 17 Miscellaneous27.. MUFFLER29.. VIBRATION ISOLATORS29.. BATTERY29.. Group 21 Generator Equipment31.. MAIN CIRCUIT BREAKER (AC)33.. OIL PRESSURE SENDER33.. TANK LEVEL GAUGE33.. Group 25 Generator Components35.. MAIN ROTOR37.. MAIN STATOR37.. OUTPUT LEAD TERMINAL BLOCK37.. END BELL/BEARING CARRIER37.. GENERATOR END ASSEMBLY COMPLETE38.. Group 26 Generator Control Components39.. DC WIRE HARNESS41.. DISPLAY PANEL41.. Index43.. Request for SRT Review iii ForewordThe Standard Repair Times (SRT) in this manual represent the time required to perform service repairson Onan Engine and Generator Sets.

3 These Times are representative of an average mechanic in a typicaldealer or distributorship using the prescribed hand tools, equipment, and all available service tools andequipment required to perform quality repairs and do all necessary use of this manual will: Encourage uniform terminology throughout the Cummins/Onan organization Standardize Repair Order job description write-ups Provide shop managers with a guide for establishing flat rate quotations Serve as a basis for Onan Corporation, Inc. to establish its warranty labor obligationsReporting of errors, omissions, and recommendations for improving this publication is encouraged. Sendyour suggestions or comments to:Onan Corporation1400 73rd Avenue NEMinneapolis, MN 55432 Attn: Service Department iv General InformationStandard Repair Times (SRT) are lists of work tasks (procedures) and the time required to perform thosetasks. The procedures list the work tasks required to be sure an engine or generator set is ready to returnto service at the lowest possible cost to the customer.

4 A Standard Repair time is equitable when the repairdescribed in the procedure can be performed in a period of time less than or equal to the Standard by ajourneyman mechanic after he/she has performed that Repair on the same model, in the same applicationat least once. Those SRT that a particular mechanic performs more frequently will often require less timethan the Standard . Conversely, those SRT that a particular mechanic does not frequently perform may re-quire more time than the Standard . Several of the procedures may be required to accurately depict all thework actually performed to return a particular engine or generator set to service because the Repair of aparticular engine or generator set is often unique in light of the complaint, failure model, progressive dam-age, condition of the parts and customer desires. To allow for differences in the time required to performa Repair because of interference by the application, a Service Accessibility Code Scheme has been of Standard Repair TimesThere are three types of SRT.

5 Most often at least one of each type is necessary to accurately depict therepair. The three types are: Administrative Troubleshooting RepairAdministrative SRTA dministrative SRT are intended to provide time to move the vehicle engine or generator set to and fromthe work area, fill out the Repair order, record SRT used, etc. It is intended that an administrative SRT beused only once for each Repair order. There are two administrative SRT found in this manual in Group 00 Complete Engine. One of the administrative SRT is to be used when the Repair takes place in a shop oper-ated by the repairing location. The other administrative SRT is to be used when the Repair takes place awayfrom the shop operated by the repairing location (road repairs). The time for the road Repair administrativeSRT is greater to allow for loading and unloading tools, equipment, parts, etc. from the service truck. v Troubleshooting SRTT roubleshooting SRT are found only in Group 00 Complete Engine.

6 These SRT are intended to be usedwhen diagnosing and analyzing engine, generator set or component failures. Troubleshooting SRT are bro-ken down in to logical numbered steps. The time for each step is cumulative with successive steps, includ-ing the time for the appropriate preceding step(s). Some troubleshooting SRT contain time to remove andinstall components to perform the check(s) listed. Most do not. If a troubleshooting SRT does NOT includerequired component removal and installation, it is intended that the SRT for the removal and installationof that component be in addition to the troubleshooting SRT. Refer to the following example:ProcedureProcedureSRTN umberDescriptionHours00 055 Troubleshoot Lubricating Oil Consumption ExcessiveIncludes: 01 Oil consumption report For external oil leaks For overfilled oil pan Oil specifications For fuel contamination Oil change interval For engine oil in torque converter 02 Perform checks in Step Check: Oil temperature Air compressor oil consumption Turbocharger seal Crankcase blowbyIn the above example, the time required to perform the checks in Step 01 is hour.

7 If the problem is notlocated while performing the checks in Step 01, an additional hour is allowed to perform the checks inStep 02 for a total of hour. The total troubleshooting time appropriate is the time indicated in the columndirectly in line with the final step required to locate the problem. The step required to locate the problemmay or may not be the last step shown in the troubleshooting SRT. Each step contains information as towhich steps are SRTR epair SRT make up the majority of this manual. These are the SRT that cover the actual Repair work. Thetime shown on the same line as the SRT code and title is the total time for that Repair Combined TimesStandard Repair Combined Times (SRCT) provide for the combining of the three types of SRT under onecode so that, if appropriate, the user can identify the work performed with fewer SRT codes. vi SRT Coding SystemEach SRT has a unique code so that SRT data can be computerized. The numbering system used is com-mon to all the SRT manuals for all Onan engines and generator sets.

8 The portion of the system shown inthe manual contains three segments: Group Number Procedure Number Step NumberGroup NumbersGroup numbers (the first two digits in the SRT code) are used to identify major engine sample list below explains the group numbers used in SRT NumbersThe procedure number consists of three digits. The first digit provides guidance as to the category of therepair. The second and third digits, shown as XX in the following list, are sequential numbers or alpha letterswithin the of GroupSpecific Re-pair NumberDescription ofCategory00 Complete Engine or Genset01 Cylinder Block0 XXTroubleshooting02 Cylinder HeadONLY in Group 0003 Rocker Levers1 XXRemove and Install04 Cam Followers/Tappets2 XXRebuild05 Fuel System3 XXReplace06 Injectors and Fuel Lines4 XXClean and VisuallyCheck or Inspect forReuse07 Lubricating Oil System08 Cooling System5 XXMachine/Ream/Dowel/09 Drive UnitsSleeve10 Intake Air SystemModify/Cut/Lap11 Exhaust System6 XXAdjust/Calibrate12 Air (Compressed) System13 Electrical Equipment7 XXTest14 Engine or Generator Set Testing15 Instruments and Controls vii GroupNumberContents of GroupSpecific Re-pair NumberDescription ofCategory16 Mounting Adaptations17 Miscellaneous9XX(SRCT in Group 99)

9 General/Miscellaneous21 Generator Equipment22 Hardware25 Generator Components26 Generator Control Components27 Transfer Switches99 SRCTStep NumbersWhile all SRT codes will contain a Group and Procedure number, only those procedures that are brokendown into steps have step numbers. The step numbers are sequential within a OrganizationThere is an alphabetic index in the back of the manual. Within a particular group the procedures are ar-ranged in alphabetical order by title, thus are not in code numeric is also a numerical index in which the procedures are arranged in numeric order and not in alphabeti-cal a procedure, the user will note that some lines are indented. This indentation is intended to indicatethat the sub-tasks are part of the task under which they are SRT Objectives and PhilosophyThe objective of Cummins/Onan SRT program is to provide credible and equitable labor time standardsand procedures to the worldwide Cummins/Onan service SRT is credible when the procedure accurately depicts the work that must be performed to accomplisha quality engine or generator set SRT is equitable when it can be performed in a period of time less than or equal to the Standard by ajourneyman mechanic after he/she has performed that Repair at least establish credible and equitable SRT with sufficient flexibility to account for differences in complaints,failures, progressive damage, customer desires, etc.

10 , SRT have been structured using the following con-siderations: What must ALWAYS be done to the engine or generator set to perform the work. What MAY have to be done to the engine or generator set parts dependent on their condition. What MAY have to be removed to access the engine or generator set. viii How difficult it is for the mechanic to reach the engine or generator set even after the interfering applica-tion hardware has been the most frequent use of SRT information is the Onan Warranty System, it is Onan s intent that theSRT be applicable to repairs conducted for any SRT s are developed, it is assumed: That all the required tools, equipment, and supplies are available in sufficient quantity and in operatingcondition. That required Onan Service Manuals are available to the mechanic are being used. That the correct parts are available when the mechanic needs Standard Repair Times are DevelopedSRT s are developed from time studies conducted in the field and Onan Technical Service Personnel.