Onan DJB Operator'S Manual Download Page 2

Page: 2 / 41

Table of Contents

SECTION

TITLE

PAGE

SAFETY PRECAUTIONS

Inside Front Cover

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GENERAL INFORMATION

1-1

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How to Obtain Service

1-1

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Model Identification

1-1

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SPECIFICATIONS

2-1

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CONTROL DESCRIPTION

3-1

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Control Panel Components

3-1

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Voltage Reconnection with Optional Instruments

3-2

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INSTALLATION

4-1

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Installation Requirements

4-1

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Generator Set Location

4-1

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Mounting

4-1

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Ventilation

4-3

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Exhaust

4-3

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Fuel Tank and Lines

4-6

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Injection Pump Adapter Assembly (DJE only)

4-7

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Oil Drain

4-7

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Electrical Connections

4-7

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Balancing Loads

4-8

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Grounding

4-11

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Switchboard

4-11

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Reconnectible Generators

4-11

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Battery Connections

4-11

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Optional Alarm

4-12

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Remote Start-Stop Switch (Optional)

4-12

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OPERATION

5-1

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Pre-Starting

5-1

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Pre-Heating and Starting

5-2

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Stopping

5-3

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Automatic Starting and Stopping

5-3

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Applying Load

5-3

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Exhaust System Inspection

5-3

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Break-In Procedure

5-3

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Safety Devices

5-3

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Exercising Unit

5-4

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Engine Ratings

5-4

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High/Low Operating Temperatures

5-4

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Dust and Dirt

5-5

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High Altitude

5-5

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Out-of-Service Protection

5-5

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Returning the Set to Operation

5-5

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ADJUSTMENTS

6-1

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Centrifugal

Switch

6-1

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Governor

6-1

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Charge Rate Adjustment

6-1

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Valve Clearance Adjustments

6-2

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Summary of Contents for DJB

Page 1: ...967 0121 2 91 Printed in U S A Electric Generating Sets GenSets Operator s Manual...

Page 2: ...lectrical Connections 4 7 Balancing Loads 4 8 Grounding 4 11 Switchboard 4 11 Reconnectible Generators 4 11 Battery Connections 4 11 Optional Alarm 4 12 Remote Start Stop Switch Optional 4 12 5 OPERAT...

Page 3: ...s 7 1 Governor Linkage 7 2 Crankcase Breather Tube 7 2 Crankcase Breather 7 2 Cooling System Maintenance 7 2 Fuel Pump Sediment Bowl 7 3 Air Cleaners 7 3 Contractor Model Air Cleaner 7 3 Optional Oil...

Page 4: ...n 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 manifolds movin...

Page 5: ...OR DIESEL For the name of your local Cummins Onan or Onan only distributor in the United States or Canada call 1 800 888 ONAN this automated service uses touch tone phones only By entering your area...

Page 6: ...ts BCI Group Cranking Performance Amp Hr Capacity Range Size at 0 F 17 C 20 hour rate 32 F 0 C and warmer 2 6 1 450 amps 105 0 F 17 C and warmer 2 6 2 560 amps 135 25 F 32 C and warmer 2 6 5D 800 amps...

Page 7: ...Cranking Performance Amp Hr Capacity Range Size at 0 F 17 C 20 hour rate 32 F 0 C and warmer 2 6 1 450 amps 105 0 F 17 C and warmer 2 6 2 560 amps 135 25 F 32 C and warmer 2 6 5D 800 amps 190 GENERAT...

Page 8: ...CONTROL PANEL ES1972C START STOP SWITCH KNOCKOUT PLUGS FOR OPTIONAL CONTROLS FIELD BREAKER DC AMMETER FUSE PREHEAT SWITCH Optional Features found on Housed Units AC Voltmeter Monitors output voltage...

Page 9: ...is equipped with a high air temperature cutoff switch HATCO to shut down the engine if engine tem perature rises above 375 F 15 F 190 5 C AC Control With Meters The AC control panel has a voltmeter am...

Page 10: ...RS OIL DRAIN OIL FILTER COOLING AIR IN SPEED ADJUSTMENT GOVERNOR SENSITIVITY ADJUSTMENTS AIR CLEANER FIELD BREAKER PREHEAT SWITCH G1246 2 FIGURE 3 4 DJE GENERATOR SET CONTRACTOR VERSION START SWITCH F...

Page 11: ...inches 76 mm clearance from the wall so the set can rock on its mounts There should be at least 24 inches 610 mm clearance around all other sides for service access MOUNTING A permanent genset instal...

Page 12: ...this set See Figure 4 3 DJE Pressure Cooling The pressure cooled DJE needs an inlet vent with an unrestricted opening of at least 3 1 2 square feet 3252 cm2 for variables Section 2 of this manual SPE...

Page 13: ...escape Use only original equipment replacement parts when servicing the exhaust system Unauthor ized modifications will also void the warranty and cancel the UL Listing CSA Certification Liability fo...

Page 14: ...TO LOAD AUTOMATIC TRANSFER SWITCH MAIN FUSE AND SWITCH MUFFLER DUCT TO REMOVE HEATED ENGINE AIR NOTE If revolving field type unit is installed in smaller than approximately 384 cu ft 11 m3 compartment...

Page 15: ...ILING AUTOMATIC LOAD TRANSFER CONTROL METER INCOMING SERVICE MAIN FUSE AND SWITCH FLEXIBLE SECTION FLEXIBLE FUEL LINE FUEL RETURN LINE BATTERIES CANVAS SECTION DUCT TO REMOVE HEATED ENGINE AIR AUTOMAT...

Page 16: ...r either the DJB or DJE generator set Use an approved flexible fuel line next to the engine Die sel engines require a fuel supply line and a separate fuel return line Install the fuel supply line from...

Page 17: ...out a supply line shutoff valve a ruptured pump diaphragm could cause oil dilution fuel loss and fuel leakage to the crankcase 3 If the maximum fuel lift must be exceeded on any in stallation consult...

Page 18: ...en the generator and the load If a test run indicates the wrong rotation of 3 phase motors in the load circuit switch the connections at any two of the generator termi nals Electrical shock can cause...

Page 19: ...nal current exceeds the nameplate rating of the generator If no 3 phase output is used usable 1 phase output is 2 3 of 3 phase kVA 3 Phase 4 Wire Wye Connected Set The 3 phase 4 wire connection produc...

Page 20: ...4 10 FIGURE 4 12 GENERATOR WIRING AND CONNECTION DIAGRAMS B200...

Page 21: ...d on the switchboard 3 Connect one ungrounded hot load wire to the un used terminal on each circuit breaker 4 On sets that generate more than one voltage ex ample 120 240 wire the voltmeter to indicat...

Page 22: ...be damaged almost in stantly if the battery charging circuit is shorted be tween resistor R21 and the B1 end of the charging winding Make certain that battery polarity is cor rect to avoid damaging o...

Page 23: ...IRE SIZE DISTANCE 18 1 02 mm to 65 ft 20 m 16 1 29 mm to 100 ft 31 m 14 1 63 mm to 150 ft 47 m 12 2 05 mm to 280 ft 87 m ES1970C REMOTE CONTROL TERMINAL BLOCK AT GENERATOR MOMENTARY CONTACT SWITCHES S...

Page 24: ...ting the generator set Oil Recommendations The use of quality engine lubricating oils combined with appropriate oil drain and filter change intervals are criti cal factors in maintaining engine perfor...

Page 25: ...ON PUMP RETURN LINE FITTING DJB FUEL SYSTEM BLEEDING DJE FUEL SYSTEM BLEEDING FS1854C WORK TRANSFER PUMP PRIMING LEVER UNTIL FUEL FLOWS FROM RETURN LINE OF INJECTION PUMP RETURN LINE Recommended Fuel...

Page 26: ...be nec essary to maintain preheating for two minutes after the engine starts to obtain firing or smooth out cylin ders especially at no load or light loads NOTE When remotely starting the set the swit...

Page 27: ...rect its cause Press the reset button on the control panel before restarting Hot oil can cause severe personal in jury Do not check the oil level while the generator set is running wait until the gene...

Page 28: ...oil flows freely 2 Use fresh fuel Protect against moisture condensa tion 3 Keep fuel system clean and batteries in a well charged condition 4 Partially restrict cool air flow but use care to avoid ov...

Page 29: ...muffler exhaust line etc and repair as necessary Exhaust gases contain carbon monoxide which may cause severe personal in jury or death Before operating the generator set make certain the exhaust line...

Page 30: ...INCH 51 mm GOVERNOR The governor controls engine speed On a 4 pole gen erator engine speed equals frequency multiplied by 30 Thus 1800 rpm generates 60 hertz Preferred engine speed does not vary more...

Page 31: ...Batteries present the hazard of explo sion which can result in severe personal injury Be cause batteries produce explosive gas do not smoke or allow any flame sparks or arc producing devices in the ba...

Page 32: ...valve clearance with the locknut which secures the rocker arm to the cyl inder head see Figure 6 4 Loosen this locknut to increase clearance tighten it to reduce clearance FIGURE 6 4 VALVE CLEARANCE A...

Page 33: ...the starting batteries at least every two weeks Make certain that connections are clean and tight A light coating of non conductive grease will retard corrosion at terminals Add distilled water t o ke...

Page 34: ...turer s recommendations before using any lubricants or solvents near the ball joints Fumes from this cleaner may present the hazard of fire or explosion which can cause se vere personal injury or deat...

Page 35: ...tion remove hose clamp breather hose breather cap clamp and insulator halves to release breather cap and valve assembly Figure 7 4 Wash cap valve assembly and baffle in suitable solvent Dry and reinst...

Page 36: ...place FIGURE 7 5 FUEL PUMP SEDIMENT BOWL FS1115 FUEL PUMP AND FILTER BODY FILTER GASKET BOWL AIR CLEANERS After every 50 hours of operation remove and clean the filter element Figure 7 6 After washing...

Page 37: ...7 5 FIGURE 7 7 DJE CONTRACTOR MODEL AIR CLEANER FS1853C COVER BAFFLE ELEMENT THUMBSCREW CLAMP DUST CUP PRE CLEANER...

Page 38: ...ative cable first before beginning any maintenance work on the engine generator control panel automatic transfer switch or associated wir ing Stop the engine and drain the crankcase oil while the en g...

Page 39: ...9 OIL LEVEL INDICATOR LS1181 ALWAYS REPLACE CAP TIGHTLY OR OIL LEAKAGE MAY OCCUR CAP AND OIL LEVEL INDICATOR KEEP CRANKCASE OIL AT THIS LEVEL NEVER OPERATE ENGINE WITH OIL BELOW THIS LEVEL FULL LOW O...

Page 40: ...he exhaust system audibly and visually each day or each time the generator is started whichever is sooner With the generator set running momentarily open the ac cess cover to inspect the muffler Shut...

Page 41: ...adjust valve clearance after first 50 hours on new and over hauled engines and then adjust valve clearance each 500 hours thereafter 8 Inspect exhaust system Inspect generator set Check fuel supply se...

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