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Onan JB Series User Manual

Onan JB Series
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OPERATOR'S
MANUAL
: I
FOR
JB
SERIES
ELECTRIC GENERATING SETS
FORM NUMBER
967-0123
ISSUE DATE
(Spec
AA)
Printed
in U S. A
2-77
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Onan JB Series Specifications

General IconGeneral
Frequency60 Hz
Fuel TypeGasoline
Voltage120V
Power Output7000W
Engine Type4-Stroke OHV

Summary

Safety Precautions

Extreme Caution with Fuels

Handle gasoline, gaseous, and diesel fuels with extreme caution due to fire and explosion hazards.

Guard Against Electric Shock

Take precautions against electric shock by removing power and using protective measures.

Battery Servicing Precautions

Avoid smoking near batteries as they emit explosive hydrogen gas.

Exhaust Gas Toxicity

Ensure proper ventilation and exhaust system to prevent toxic gas exposure.

Unit and Area Cleanliness

Keep the unit and surrounding area clean to prevent overheating and fire hazards.

Protect Against Moving Parts

Be aware of moving parts to avoid entanglement from loose clothing.

General Information

Model Identification

Identify the specific generator set model and specification number from the nameplate.

General Safety Warning

Qualified personnel must perform installation and service to avoid injury or damage.

Specifications

General Unit Specifications

Provides dimensions, weight, and general characteristics of the generator set.

Engine Details

Lists engine specifications including displacement, bore, stroke, and RPM.

Capacities and Requirements

Details battery voltage, oil capacity, and ventilation requirements.

Generator Specifications

Outlines generator output ratings, voltage, phase, and exciter type.

Tune-Up Specifications

Carbon Monoxide Hazard

Warns about the lethal danger of carbon monoxide and symptoms of inhalation.

Description

General Unit Description

Overview of the Onan JB Series generating set, engine, and AC generator.

Engine Details

Describes the two-cylinder, air-cooled engine's displacement and compression ratio.

AC Generator Construction

Explains the four-pole, brushless exciter AC generator design and components.

Voltage Regulator and Controls

Voltage Regulator Operation

Details the solid-state voltage regulator components and their function.

Control Panel Overview

Describes standard and optional controls found on the typical control panel.

Control Panel Details

Standard Controls and Instruments

Brief description of standard controls like Start-Stop switch and oil pressure gauge.

Optional Controls and Instruments

Describes optional instruments such as AC voltmeter and running time meter.

Voltage Reconnection Advice

Provides caution for voltage reconnection with optional instruments and service center contact.

Installation

General Installation Requirements

Lists essential installation requirements including level surface, air flow, and connections.

Location Selection

Guidance on choosing a protected, dry, clean, and well-ventilated location for the set.

Mounting Procedures

Details requirements for a sturdy, level mounting base and cushion assembly.

Ventilation and Cooling

Explains the need for adequate air circulation for engine and generator cooling.

Exhaust, Fuel, and Electrical Systems

Exhaust System

Instructions for venting exhaust gases and ensuring system integrity.

Fuel System Connections

Guidance on fuel tank installation, fuel line connections, and gaseous fuel setup.

Electrical Connections

Details on connecting load wires, ground lead, and main switch.

Standby Installation

Requirements for standby service including transfer switches and load balancing.

Electrical Connections and Battery

Load Transfer Switch

Illustrates a typical load transfer switch connection for line and generator.

Generator Output Lead Configurations

Explains generator output lead markings and reconnection options.

Switchboard Connections

Details connections for ammeters, voltmeter, and circuit breakers on a switchboard.

Battery Charge Rate Adjustment

Guidance on adjusting the battery charging rate and resistor tap settings.

Generator Wiring Diagrams

Generator Connection Diagrams

Wiring and connection diagrams for various voltage codes and configurations.

Battery and Remote Starting

Battery Polarity and Connections

Details battery connections, polarity, and precautions against reversed connections.

Remote Start-Stop Switch Wiring

Instructions for wiring a remote start-stop switch using a 3-wire connection.

Operation - Pre-Starting and Fuel

Pre-Starting Checks

Essential checks of oil, fuel, cooling, and electrical systems before starting.

Crankcase Oil Recommendations

Specifies recommended oil types, weights, and API service designations.

Recommended Fuel

Guidance on using clean, fresh regular grade automotive gasoline.

Initial Start Procedure

Steps for the initial start, including checking oil, fuel, and potential spark plug fouling.

Operation - Starting, Load, and Protection

Starting and Stopping Sequence

Details the manual, mechanical, and electrical sequence for starting and stopping the unit.

Applying Load to Generator

Guidance on connecting loads gradually and avoiding overloading the generator.

Standby Plant Exercise

Recommendation to operate standby sets weekly to ensure proper function.

Emergency Operation & Break-In

Procedure for emergency operation and break-in process with load variations.

Out-of-Service Protection

Measures to protect the set when it will be out of service for over 30 days.

Operation - Environmental and Fuel Switching

Environmental Operating Conditions

Advice for operating in high/low temperatures, dust, dirt, and high altitudes.

Gas-Gasoline Fuel Switching

Procedure for switching between gas and gasoline fuel modes and related adjustments.

Adjustments - Ignition and Carburetor

Check Breaker Points

Instructions for checking, gapping, and replacing ignition breaker points.

Carburetor (Gasoline) Adjustments

Details on adjusting main fuel and idle speed needles for gasoline carburetors.

Carburetor Float Adjustment

Procedure for adjusting the float level in the Zenith carburetor.

Adjustments - Carburetor and Choke

Carburetor (Gas-Gasoline) Adjustments

Details for adjusting gas and gasoline main and idle adjustments.

Choke Adjustment

Table and guidance for adjusting the choke based on ambient temperature.

Adjustments - Choke and Governor

Onan Thermo-Magnetic Choke

Explanation of the thermostatic choke operation and adjustment procedure.

Governor Adjustment

Instructions for adjusting governor speed and sensitivity for stable engine operation.

General Maintenance

Maintenance Schedule

Factory recommended maintenance schedule based on operating hours.

AC Generator Maintenance

Periodic inspection of the rotating rectifier assembly for dust and proper torque.

Batteries Maintenance

Guidance on checking battery condition, connections, and electrolyte levels.

Oil Filter Change

Procedure for safely removing and installing the oil filter.

Maintenance Procedures - Air Cleaners and Oil

Air Cleaner Maintenance

Instructions for cleaning and maintaining foam and dry element air cleaners.

Oil Level Indicator

Explanation of the oil level indicator and warnings about checking while running.

Maintenance Procedures - Breather and Spark Plugs

Crankcase Breather Maintenance

Procedure for cleaning and reinstalling the crankcase breather assembly.

Spark Plug Gap Adjustment

Illustrates how to correctly set the spark plug gap using a gauge.

Troubleshooting Guide

Starting System Troubleshooting

Common issues and causes related to the generator's starting system.

Ignition System Troubleshooting

Diagnosing problems with timing, spark plugs, coil, and wires.

Fuel System Troubleshooting

Identifying and resolving issues with fuel supply, mixture, and filters.

Internal Engine Troubleshooting

Troubleshooting engine internal components like valves, rings, and bearings.

Cooling System Troubleshooting

Addressing overheating and coolant issues specific to air-cooled systems.

Lubrication System Troubleshooting

Diagnosing problems with oil pressure, pump, and oil level.

Throttle and Governor Troubleshooting

Resolving issues related to linkage, speed, and governor sensitivity.

Parts Information

Running Replacement Parts List

List of common external parts requiring replacement due to normal wear.

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