Onan Mja series User manual

1

MJA

CONTROL

WIRING

DIAGRAM

(No low

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Circuit)'

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INTRODUCTION

Tbis

manual contains information

for

proper

maintenance,

servicing

and

overhaul

of

MJA, MJB,

and

MJC

series

electric

generating

plants.

It

doesn't

include

installation

and

operation

instructions.

Unless

otherwise

stated,

these

instructions

apply to

all

standard

plants

of the MJA, MJB,

and

MJC

series.

Some

details

may not apply to

special

models

with modification

specified

by the

purchaser.

How-

/'i.

ever,

by using the

instructions

and

recommendations

given

in

tbis

manual

as

a

general

guide" the MJA, MJB,

or

MJC

generating

plant

can

be

properly

maintained

and

repaired.

You

will, of

course,

be

using

tbis

manual

primarily

for

reference

when

servicing

MJA, MJB,

and

MJe

generat-

ing

plants.

Tbis

is

what

it

was

designed

for.

But,

inaddi-

tion,

ONAN

recommends

that

you

study

the whole

manual.

It

will

help to acquaint you with the

plants

you'll

be

work-

ing on and

save

time

later

on in

servicing.

,If

possible,

use

a

parts

catalog

with the

service

man:ual.

The

parts

catalog will give you a good

picture

of

assembly

and

disassembly

and

help identify

plant

components. Since

the

fir

st

and

most

important

part

of

repair

work

is

correct

diagnosis

of the trouble,

trouble-shooting

charts

are

in-

cludedtbroughout

tbis

manual

to

aid

diagnosis.

Because

of

the

variety

of engines,

generators,

and

controls

discussed

in

tbis

manual,

some

sections

don't

applyto

all

models.

If

.a

section

or

paraf'.'aph

applies

only

to

certain

models,

tbis

is

statedat

the

bf

j.nningof the

section.

Check

tbis

before

t"l

beginning

repair

-

,)

Throughout

./

this

manual, the flywheel

en4

of

the enginewill

be

called

the

"Front"

and

the

fuelpump'side

designated

the

"Left

Side".

.~

IONAN'MODElNUMBERING

-SYSTEM'

YYPICAlMODEl:

SMJB.1R/96B

MOOU-

"SMJB~l

R

/968

TiTTiT~

S.EENOTE- 1 2 3

4567

NOTE

1 -

Plant

Capacity

in

Kilowatts

-For

Example.:

3

-3KW

30.5

-3.

5KW

5 -

5EW

;-:;.,

2

-Plant

Ser

ies

3 -

60

Cycle

Electrical

.output

No.

of

Code

Volts

Phase

Wires

1

120

1 2

2

240

1 2

3-*

120/240

1 3

4 120/2.08 1 3

~5

240

3 3

5D

(delta)

120/240

3 4

50

added

to

code

designates

50

cycle

i.e.

1

becomes

51.

4-Type

·of

Starting-R-

RemoteE

-Electric

M-

Manual

'S

-

Diagonal

Line

-

Separates

Basic

Model

from

Specification

Number

and

Letter.

6

-Specification

Number

-

Denotes

Customer

Requested

Deviations

from

Standard

Model.

'1-Specifica'tif)fl

Letter

-

Advances

.with

ONANchanges.

*

-,5M:JB

--

Some

models

have

generators

reconnectib1e

for

either

code

1,

2,

or

3;

these

models

are

designated

3C.

-'705

MJB

&

MJC

--AlICode

.3

models

are

reconnectible

for

either

code

1,

.2,

or

3,

See

the

plant

operators

manual

V"'''.ALN

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on705MJB

Spec

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and

Spec

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3

Q4SXINIB and 06SXINIB EXCITER

WIRING

DIAGRAM

06SX

Spec

B

Static

Exciter

Wiring

Diagram

in

Pictorial

(With

residual

reset

switch)

h(

~~

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in

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TABLE

OF

CONTENTS

SECT.

INDEX

.................................•........

1.

GENERATING PLANTS

(Early

models

shown)

.....

"

2.

PERIODIC SERVICE

...................•........

3. THE ENGINE

•................................•.

3.

1 Cooling

System

............................

.

3.2

Fuel

System

..............................•..

3.3

Ignition

System

...................•.......••.

3.4

Governor

System

........................

~

•..

3.

5

Oil

System

..............................•.••

3.

6

Starting

System

............................

.

3.7

Cylinder

Heads

and

Valves

••................•

3.8

Pistons,

Connecting

Rods

&

Cylinders

.•.......

3.9

Engine

Disassembly

........................

.

4. GENERATOR, REVOLVING

FIELD

(705MJB, MJC)

...............................

.

5. GENERATOR, REVOLVING

FIELD

(3MJA, 4MJA

and

5MJB)

•.......................

6. CONTROL SYSTEM

.............................

.

7. ASSEMBLY TORQUES

...........................

.

8.

SPECIAL

TOOLS

.............................•...

9. TABLE

OF

CLEARANCES & DIMENSIONS

.••......•

10.

~G

DIAGRA~

..................•..........

Trouble

Shooting

Charts

PAGE

1.

The

Engine.

. . . . . .

..

11

2.

Cooling

System

..

.

..

26

3.

Fuel

System

.......

40

4.

Ignition

System

...

. . 54

5.

Governor

System

...

59

6.

Oil

System

...

. . . .

..

64

7.

Starting

System

....

71

8.

9.

10.

11.

12.

Cylinder

Head

and

Valves

Pistons,

Connecting

Rods

and

Cylinders.

. . . ••

••

Revolving

Field

Genera-

tOr

••.........•....

~.

Magneciter

•...•......

Revolving

Armature

Gen-'

erator....

..

......

.....

PAGE

4

6

9

10

19

28

41

57

60

66

73

80

85

93

109

119

128

129

130

133

PAGE

78

84

105

107,

117

--

U'!>::t"'!l'1.l.R.

£,,A\,.,J..l.£,n

4:

INDEX

SUBJECT

Ai?

Silencer

Anti-Flicker

Point

Set

Armature,

Generator

Automatic

Choke

Back

Pressure,

Exhaust

Batteries

Battery

Charging

Rev.

Armature

Models

Rev.

Field

Models

Battery

Charging

Rectifier

(Revolving

Field)

Battery

Charging

Resistor

(Revolving

Field)

Battery

Polarity

(Rev.

Field)

Bearings,

Camshaft

Bearings,

Connecting

Rod

Bearings,

Main

Break-In

Period

Breather

Valve

Camshaft

Bearings

Center

Gear

Carburetor,

Gasoline

Centrifugal

Switch

(Start-Disco,nnect)

Choke,

Electric

Compression

Rings

Connecting

Rod

Connecting

Rod

Bearing

Control

System

Cooling

Crankcase

Breather

Crankshaft

Bearings

Gear

Removal

Cylinders

Cylinder

He.ad

Distributor

Electric

Starting

Emergency

Relay

Exciter

Cranking

ExballS~

Back

Pressure

Flyballs

Flyball

Governor

SECTION

3.2.6

5.1.

4

5

3.2.4

3.2.7

3.6

6.2.2

6.3.2

6.3.2.1

6.-3.2.2

6.3.2

3.9.4.4

3.8.7

3.9.5.4

3.8.9

3.5.7

3.9.4

3.9.4.4

3.9.3

3.9.4.3

3.2.5

6.3.1.3&

3.3

3.2.4

3.8.5

3.8.6

3.8.7

6

3.1

3.9.6

3.5.7

3.9.5

3.9.5.4

3.9.5

3.9.5.1

3.R.2

3.7

3.3.4.3

3.3

6.2.3.2

&

6.3.3.4

5

3.2.7

3.9.3

3.4

&

3.9.3

SUBJECT

Flyball

Spacer

(see

camshaft

gear)

Fly.vheel

Fuel

Pump

Fuel

Strainer

Gasoline

Carburetor

Gear

Cover

Generator

Blower

Generator

Brush

Rig

Governor

Arm

Governor

Cup

Governor

Linkage

Governor

Shaft

Governor

Shaft

Bearings

Governor

Spring

Governor

"Thrust

Ball

Brg.

Governor

Yoke

Heat

Exchanger

Hi-

Temp.

Switch

Ignition

Breaker

Points

1

Cylinder

2

Cylinder

4

Cylinder

Ignition

Coil

1

Cylinder

2

Cylinder

4

Cylinder

Ignition

Condenser

1

Cylinder

2

Cylinder

4

Cylinder

Ignition

Latching

Low Oil

Pressure

Switch

Revolving

Armature

Revolving

Field

Magneciter

Reactors

Rectifiers

Residual

Re-Set

Switch

Needle

Bearings,

Governor

Shaft

Oil

BY··.:;:'c.]8

Valve

SECTION

3.9.1

3.2.1

3.2.3

3.2.2

3.2.5

3.9.2

4

5

3.4&

3.9.3

3.4

3.9.3

3.4

3.9.2.1

3.9.2

3.4

S.9.2

3.9.2

3.1.4

6.2.3.1

&

6.3.3.1

3.3.2

3.3.3.3

3.3.4

3.3.2

3.3.3.5

3.3.4.4

3.3.2

3.3.3.4

3.3.4.5

6.3.1.2

6.2.3.2

6.3.3.2

4.2.3

&

4.3.3

4.3.3.1

4.3.3.2

4.3.1.1

3.9.2

3.5.3

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CONTROL

WIRlNGDIAGRAM

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(With

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INDEX

(CONT)

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to

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100:1

~,

SUBJECT

Oil

Control

Rings

Oil

Filter

Oil

Grade

Oil

Lines

Oil PreSSUIe Gauge

Oil

Pump

Oil

Pump

Intake

Cup

Oil

Seal,

Crankshaft

Rear

Oil

Seal,

Gear

Cover

Oil Seal,

Governor

Shaft

Oil

Seal,

Valve

Stem

Oil

System

Periodic

Servicing

Pistons

Piston

Bushing

Piston

Rings

Place

Bolt

Preventive

Maintenance

Rear

Bearing

Plate

Reconnection

Block

Remote

Starting

Revolving

Armature

Revolving

Field

Residual

Reset

Switch

Reverse

Current

Relay

Revolving

Armature

Gener-

ator

Armature

Ball

Bearing

Brushes

Commutator

Field

Commutator

Collector

Rings

Resistor

(Charge

Circuit)

ReSistor

(Emergency

CirCuit)

Revolving

Field

Generator

Air

Baffle

Battery

Charging

Winding

Brushes

Bearing

EXCiter

Rotor

Collector

Rings

SECTION

'3.8.5

3.5.6

3.5.1

3.5.4

3.5.5

3.5.2

3.5

3.9.5.5

3.9.2.2

3.9.2

3.7.5

3.5

2

3.8.3

3.8.4

3.B.6

3.B,5

7

2

3.9.5

6.3.2

6.2

6.3

4.3.1.1

6.2.2.1

5

5.3,1

5.1.2&

5.3.5

5.1.1

5.1.

3 &

5.3.3

5.3.2

5.1.3

&

5.3.4

6.3.3.2

6.3.3.5

4

4.5,

4.3.2.3

4.2.1

4.2.2

4.2.3

4.3;2

4.2.4&

4.3.2.4

SUBJECT

Stator

Ring

Gear

Rocker

Arm

Rocker

Box

Cover

Rocker

Box

Cover

Oil

Line

Run-In

Period

Solenoid

Shift

Starter

Spark

Plugs

Start-:-Disconnect

Relay

Start

Ignition

Relay

Starting

Motor

Starting

System

Start

Solenoid

Static

Exciter

(see

Magne-

citer)

Stop

Relay

Thermostat

(Coolant)

Thrust

Washer,

Camshaft

Thrust

Washer,

Crankshaft

Valves

Clearance

Adjustment

Guide

Push

Rods

Seats

Spring

Retainer

Spring

Retainer

Lock

Stem

Cap

Stem

Oil Seal

Tappet

Water

Pump

Wrist

SECTION

4.3.2

3.5.1.1

3.7.5

3.5.4

3.B.9

3.6

3.3.5

6.2.1.3

6.3

..

1.1

3.6

6.2.1.1&

6.3.1.4

6.2.1.2

3.1.3.1

3.9.4.5

3.9.5.6

3.7.4.1

3.7.1

3.7.4.2

3.7.5

3.7.4.3

3.7.4.4

3.7.3&

3.7.5

3,7.3

&

3.7.5

3.7.3

&

3.7.5

3.7.3&

3.7.5

3.7.3

3.1.3.2

&

3.1.4.5

3.8.4

~

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