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My Onan Generators

Onan DJE generator repair restoration project

This is an Onan DJE 7 KW diesel generator. Go to subdirectories for detailed pictures of my restoration/repair/accessorizing this generator.

The objective here is to make a backup power generation system for my house that has acceptable levels of noise and meets electrical and fire code.

I did this in my free time while working on my algebra website.

Click here to see where the generator will be placed.

Vibration insulating carriage made of two wooden platforms

./Diesel/Carriage

Lead lined soundproofing enclosure

This enclosure was built from 1/2" plywood and is lined with 1mm thick lead sheet. It reduces noise by about 5dB and makes being close to the working generator much more pleasant. If I put a piece of plywoood in front of it, the sound reduces by 5 more dB.

Replacing starter solenoid on Onan DJE

This page describes replacement of the starter solenoid on my Onan DJE generator. Here's my post to SmokStak:

Onan DJE starting problems -- STARTED WORKING ON 'EM

A few months ago, I posted a message that my Onan DJE pictured here:

http://igor.chudov.com/tmp/onan/Diesel/

has developed starting problems. The problem is that when I flip the start switch, it makes a loud CLICK as the solenoid pulls back and pushes the gear forward, the the starter usually does not engage.

The problem got worse over time.

I finally found time to work on it (having torrential rains in the area and seeing our friend's basement flood due to 13 hour power outage also helped).

I took the enclosure apart a little.

My finding is as follows.

1. The contacts between positive and negative cable ends, and ther contacts on the genset, were corroded. I corrected that by taking them apart and applying sandpaper pads and using a copper conductive goo.

It did not help.

2. When I engage the starter switch and the gear pulling solenoid pulls back, there is no voltage on the other contact that it is supposed to close when it pulls back (the one leading to the main starter).

in other words, either the solenoid fails to pull back far enough, or the contact inside is bad.

I tried pulling it back by hand as far as I could and measuring ohms -- there is no difference.

So, to me, it is the inside contact that does not work.

I am going to take the starter off and try to open it up carefully in my garage. How can I do it (just take off the wires and the main bolts that bolt its flange to the body of the generator?)

Any words of wisdom?

Further investigation showed that the problem was that the solenoid that attaches below the starter, is bad and does not close contact to run the starter.

I ordered a replacement. It was a China made "generic OEM" part. The price was $39 on eBay and $59 on partsforless website. The cost from Onan is $369!!!

I then painted the replacement and replaced the solenoid. That fully cured the generator. The last pictures show what happened in the old solenoid -- the contacts were totally burned out.

Diesel ==> Starter Repair ==> Prior To Repair

I made these pictures to show the state of the starter prior to disassembly, and also to aid me in reassembly so that I do not mess anything up.

Fuel tank made of a steel jerry can

./Diesel/fueltank

The generator is in my garage, after unloading

./Diesel/home

Diesel ==> home ==> exhaust

./Diesel/home/exhaust

My first shot at making an electrical panel. Will be replaced by aluminum.

./Diesel/panel

Replacement of a defective fuel shutoff solenoid by a FW Murply solenoid

These are pictures of the FW murphy solenoid RP2307B. First on my desk, and second, installed properly in the engine compartment. I made a 1mm thick steel plate to hold it and close off the opening for the old solenoid. It is all bolted together with 1/4" steel bolts and holds very tight. The engine now starts and stops whenever I want! All the old safety shutdowns: low oil pressure, high temp, overspeed, still work.

Nice pictures of the unit after all repairs were done. Fully working condition.

./Diesel/z01_repaired

Onan diesel Generator installed at its permanent location!

Today, my FIL and myself moved the generator into its spot. It is behind the house, very close to the electrical meter and the panel inside. It is located next to the deck, which shields most of the noise.

I measured noise with a sound level meter.

Here are the pictures of the Generator installed at its permanent location.
Noise Levels:

10 ft in front of the generator -- 73 dB.
Across the deck, near house -- 63 dB.
Inside the house -- can be barely heard, with effort

The piece of plywood that is behind the genset, goes in front of it when the generator is to be run. It reduces noise by whopping 5 dB.

Pictures of the final exhaust stack with the generator running.

These are pictures of my exhaust stack with the generator running. There is a flexible exhaust hose rather close to the exhaust manifold. The stack is supported by a galvanized steel angle. It is about 6" away from the deck.

MEP 017A

./MEP-017A

engine

./engine