IP i-. FOR ONAN ELECTRIC GENERATING PLANTS SERIES NOTE!! The ONAN Manual and/or Parts Catalog only has been supplied. This model series has been out of production for a number of years. Due to reasons beyond our control we no longer stock or supply the engine manufacturers Manual or Parts Catalog. However we believe they are available direct from the engine manufacturer providing you fumish the SERIAL NUMBER and SPEC from the engine manufacturers nameplate on the engine. Refer to Parts Catalog and order from manufacturer as indicated under "Instructions for Ordering Repair Parts". DIVISION OF STUDEBAKER CORPORATION MINNEAPOLIS, MINNESOTA 9-5 8AE Printed in U.S.A.
DZB SERIES This parts catalog applies to the standard ONAN DZB Series electric generating plants. Prior to Spec D Models are powered by a Hercules Series DD-9 Engine, and beginning Spec D are powered by a Hercules Series D-500, which is more completely described in the Hercules manual. Basically, the engine is a cylinder, water cooled, diesel (compression ignition) type. The cylinder bore is -/ inches, piston stroke is -/ inches and displacement is 9 cubic inches. Hercules Engine parts must be selected from the appropriate Hercules parts list and parts must be secured from the Hercules Motor Corporation. Engine parts that are modified or added by ONAN will be found in this ONAN list. They all have Onan part numbers and must be used in place of a like part that may be listed by Hercules in their list. "Right" and "Left" sides of the Generator, Controls and Housing are determined by FACING the Radiator (Front) End. C ONAN parts are illustrated in groups and have reference numbers which correspond to the like numbers in the list for that group. Parts illustrations are typical and should not be construed to represent a particular part number. Compare your ONAN plant nameplate MODEL and SPEC, with the Plant Data Table. Select the Parts Key No. (, etc. in the last column) that applies to your plant Model and Spec No. This Parts Key No. appears in the description of parts that differ between basic models. UNLESS OTHERWISE MENTIONED IN THE PARTS DESCRIPTION, PARTS ARE INTERCHANGEABLE BETWEEN THE VARIOUS PARTS KEYS. Plant Data Table MODEL & SPEC f ELECTRICAL DATA PARTS HOUSED UNHOUSED WATTS VOLTS CYCLES* 0DZB-R/ 0DZB-R8/ 0. 000 0/0 0 0DZB-R/ 0DZB-R8/ 0, 000 0/08 0 0DZB-5R/ 0DZB-5R8/ 0,000 0 0 5DZB-R/ 5DZB-R8/ 5, 000 0/0 0 5DZB-R/ 5DZB-R8/ 5, 000 0/08 0 5 5DZB-5R/ 5DZB-5R8/ 5, 000 0 0 KEY t - The NUMBER after the diagonal line (/) signifies standard or optional features. ( is standard). The LETTER ending the model and spec. no. is the Spec Letter and will advance with manufacturing changes, (A to B, B to C. etc.) - Applies to the AC OUTPUT CONTROL and GENERATOR Groups Only. This list covers 0 Cycle Plants only. For 50 Cycle Plants, (Check ONAN Nameplate) use only as a guide except where 50 Cycle is specified. Order parts for 50 Cycle Plants by description and be sure to give complete Onan Nameplate information.
5A- f 5B ( IA ISA \ 0 A- A FIG. -FUEL SYSTEM GROUP FIG. -COOLING SYSTEM GROUP
c FIG. -STARTING MOTOR AND BATTERY CHARGE GENERATOR GROUP FIG. -HOUSING GROUP-HOUSED PLANTS ONLY
FIG.5 -MOUNTING G R O U P - U N H O U S E D PLANTS ONLY FIG. -GENERATOR GROUP
FIG. 7 -ENGINE CONTROL PANEL GROUP (ENGINE INSTRUMENT) 5 «FIG. 8 -ELECTRICAL CONTROL PANEL GROUP (AC OUTPUT)
PARTS LIST REF. PART OUANT. USED DESCRIPTION REPLACEMENT ENGINE 00P ( (Hercules Motor Corp. D500 X ) Replaces 00P8 (D9 x ) and 00P8 (D9 x 7 and D9 x 8) General Description: Includes - Complete Cylinder Block; Oil Pan; Governor and Fuel Pump Assembly; Hand Primer Pump; Oil Pump; Oil Filter; Water Pump; Intake and Exhaust Manifold; Volt Air Intake Heater; and Flywheel Housing (Generator Adapter). Excludes - Air Cleaner & Hose; Oil Drain Assembly; Fuel Filter, Mounting Bracket & Line; Starter; Voltage Regulator & Mounting Bracket; Charge Generator, Mounting Bracket & Harness Assy.; Radiator & Hoses; Fan Blades, Belt & Guard; Air Intake Heater Solenoid, Mounting Bracket & Leads; Exhaust Muffler, Flange & Flexible Tube; Oil Pressure & Water Temperature Gauge Senders; High Water Temperature Cut off Switch; and Engine Mounts. IA A A 5A 5B 7 8 9 0 5 FIG - FUEL SYSTEM GROUP 9P75 Filter, Fuel (Fram #F-0PL) Includes Cartridge - Used Begin ONAN Serial #077. 9P7 Filter, Fuel (Hartford Mach.#00-lA)Includes Element - Used Prior to ONAN-Serial #077. 9C7 Bracket, Fuel Filter Mounting - Begin Serial #077. 9C7 Bracket, Fuel Filter Mounting-Prior to Serial#077. 9P7 Cartridge, Fuel Filter (Fram #C-0PL) Begin f ONAN Serial #077. 9-7 Element, Fuel Filter (Hartford Mach. #0) Prior to ONAN Serial #077. Elbow, Fuel Filter Outlet - 50- Prior to Spec C. 50-0 Begin Spec C. 9B77 Line, Fuel Filter to Injection Pump - Begin Serial #077 - Prior to Spec C 9B7 Line, Fuel Filter to Inj. Pump - Prior to Serial 077. 50A88 Line, Fuel Filter to Inj. Pump-Flex - Begin Spec C. 0B500 Cleaner, Air. 50- Hose, Air Cleaner. 50- Clamp, Air Cleaner Hose. 07B0 Solenoid, Intake Manifold Heater. 0A Bracket, Solenoid Mounting (With provision for mounting Injection Pump Spring). A99 Lead, Solenoid to Intake Manifold Heater-0" Long. A00 Lead, Solenoid to Starter - " Long. A7 Jumper, Injection Pump Terminal to Ground-8" Long. 50-5 Elbow, Street - Primer Pump Inlet. 505-05 Nipple, Pipe - Primer Pump to Fuel Filter - Begin 5A 50-7 ONAN Serial #077. Nipple, Pipe - Primer Pump to Fuel Filter - Prior to C ONAN Serial #077. / 9A78 Spring, Injection Pump - Replaces 5A58. 8 5B59 Flange, Exhaust Manifold. V
PARTS LIST REF. PART OUANT. USED DESCRIPTION 9 0 5 7 8 9 0 5A5 55B5 55B9 505-0A 0A 505-00 50P 50-98 50-97 50-505- 99 505-8 50P0 505-7 50- FIG - FUEL SYSTEM GROUP (Cont.) Gasket, Exhaust Flange. Muffler, Exhaust. Tube, Flexible Exhaust. Coupling, Exhaust Tube. Adapter, Oil Drain. Gasket, Oil Drain. Nipple, Pipe Close - Oil Drain - /". Valve, Shut-off - Oil Drain. Hose, Oil Drain - Specify " length when ordering. Clamp, Oil Drain Hose. Valve, Drain - Cylinder Block. Nipple, Pipe Close - Crankcase Breather - /". Elbow, Pipe (90 ) Crankcase Breather. Hose, Crankcase Breather - SPECIFY Length Req. Bushing, Fuel Filter Outlet - Begin Spec C Elbow, Fuel Line to Injection Pump - Begin Spec C ( 5 7 8 9 0 0D0 SOP 50-50C0 50C9 50-9 0B0 0C07 0C0 0C05 FIG - COOLING SYSTEM GROUP Radiator. Cap, Radiator. Valve, Radiator Drain. Hose, Engine to Radiator - Upper. Hose, Engine to Radiator - Lower. Clamp, Radiator Hose. Fan Only, Cooling. Guard, Fan - Rear Portion. Guard, Fan - Right Hand Side. Guard, Fan - Left Hand Side. 5 7 8 FIG - STARTING 9D8 9A59 5P0 50A95 0A9 9A8 9B8 A5 9P5 MOTOR & BATTERY CHARGE GENERATOR GROUP AStarter, Volt (Delco Remy #075) - Replaces 9D7 (Delco Remy #08) Cover, Starter Hole. Belt, Charge Generator and Fan Drive. Spec A Only - Order 5K Belt and Pulley Kit Begin Spec B Stud, Starter Mounting. Nut, Hex - Starter Mounting Stud. ARegulator, Voltage - Volt (Delco Remy #900). Bracket, Voltage Regulator Mtg. -Early Spec A Models. Condenser ;-. Mfd. - () Charge Generator, () Voltage Regulator AGenerator, Battery Charge - Volt (Delco Remy #00). A - For Component Parts not listed, contact your nearest Delco Remy Dealer. Supply Delco Model Number.
8 PARTS LIST REF. PART QUANT. USED DESCRIPTION ( FIG. - STARTING MOTOR & BATTERY CHARGE GENERATOR GROUP (Cont.) 0 0A5 9B59 9A5 9A 5 8B05 7 A77 A9 Nut, Hex - Charge Generator Mounting. Fan and Pulley, Generator - Piece (Replaces previously used Piece Fan, Pulley and Plate). - Spec A Only - Order 5K Belt and Pulley Kit. Begin SpecB. Strap, Adjusting - Charge Generator. Bracket, Charge Generator Mounting. Harness Assembly, Charge Generator to Voltage Regulator - Wires in Sleeving. Cable, Battery - 8" Long. " Long. FIG. -- HOUSING GROUP (HOUSED PLANTS ONLY) 0D5 0D5 05D 05D08 5 05B080 0-7 0-88 8 05D5 9 0A0 0 0A5 0A0 0A 0A 50A57 5 0P90 05C08 7 0B08 8 0B09 9 B8 0 - D 50A5 A7 05A8 Chassis, Mounting. Chassis, Mounting - Rear Section. Panel, Front End. Panel, Rear End - Excludes door. Panel, Rear Door - Includes hinge. Knob, Panel Door - Attach with machine screw. Catch, Panel Door. Panel, Top. Mounting.Assy., Front Engine - Includes parts marked * plus washers and nuts. Spacer, Front Engine Mounting. Mount, Rubber - Upper. Cup, Rubber Mount Retainer. Mount, Rubber - Lower. Stud, Engine Mounting. Mount, Vibration - Generator. Panel, Side Door - Includes Hold-down Fasteners. Bracket, Radiator - Left Hand. Bracket, Radiator - Right Hand. Frame, Battery Hold-down. Tray, Battery. Stud, Battery Hold-down. Strap, Ground - Generator Adapter to Mounting Chassis. Stop, Door.
PARTS LIST 9 REF. PART QUANT. USED DESCRIPTION FIG. 5 - MOUNTING GROUP (UNHOUSED PLANTS ONLY) C 5 7 8 9 0 5 7 8 0D5 0C78 0C79 05B089 05D 0A0 0A5 0A0 0A 0A 50A57 0P90 0'B08 0B09 B8 D A90 A7 Chassis, Mounting. Trim, Chassis - Right Hand Side. Trim, Chassis - Left Hand Side. Trim, Front Panel. Panel, Front End. Mounting Assy., Front Engine - Includes parts marked * plus washers and nuts. Spacer, Front Engine Mounting. Mount, Rubber - Upper. Cup, Rubber Mount Retainer. Mount, Rubber - Lower. Stud, Engine Mounting. Mount, Vibration - Generator. Bracket, Radiator - Left Hand. Bracket, Radiator - Right Hand. Fram e, Battery Hold- down. Tray, Battery. Stud and Wing Nut, Battery Hold-down. Strap, Ground - Generator Adapter to Mounting Chassis. FIG. - GENERATOR GROUP 0A899 0A900 0A90 0A905 0A90 0A909 50A5 0C0 0C05 0C0 0C07 B9 B9 B B Armature Assembly - Includes Ball Bearing and Drive Disc. Parts Key No. Parts Key No. Parts Key No. Parts Key No. Parts Key No. Parts Key No..... 5.. Bearing, Armature Ball. Frame only, Generator - Machined and Drilled. Parts Key No.. Parts Key Nos. and. Parts Key No.. Parts Key Nos. 5 and. Shoe, Pole. Parts Key No.. Parts Key Nos. and. Parts Key No.. Parts Key Nos. 5 and.
0 PARTS LIST REF. PART QUANT. USED DESCRIPTION FIG. - GENERATOR GROUP (Cont.) A9 A90 A50 A5 C0 C07 7 A 8 A8 9 A0 0 A0 A As F * B A57 A5 As R A7 A78 5 A0 D 7 C8 8 05B 9 B8 0 B8 C A55 0D0 0A95 Coil Assembly, Field - Set of Coils, Connected. Parts Key No.. Parts Key Nos. and. Parts Key No.. Parts Key Nos. 5 and. Rig Assy., Brush - Includes Brushes and Springs. Parts Key Nos.,, and 5. Parts Key Nos. and. Guide, Commutator Brush. Spider, Brush Rig Mounting. Block, Holder - Collector Ring Brush. Spring, Brush. Commutator Brush. Collector Ring Brush - (8) Parts Key Nos.,, and 5; () Parts Key Nos. and. Ring, Insulator - Brush Guide. Brush. Commutator. Collector Rings (8) Parts Key Nos.,, and 5; () Parts Key Nos. and. Condenser -.5 Mfd. - Parts Key Nos., and. Clip, Bearing Stop. Cover, Bearing. Bell, End. Ring, Spacer - Generator Adapter to Gen.Frame. Blower, Generator. Cover, End Bell Opening. Top and Sides (Blank). Bottom (Screened). Scroll, Air. Spacer, Air Scroll Mounting. Adapter, Generator (Flywheel Housing) Included with Replacement Engine. Eye, Lifting - Mounts on Generator Adapter. A 5 FIG. 7 - ENGINE CONTROL PANEL GROUP (ENGINE INSTRUMENTS) 0C9 08-90 08P5 0A97 0P0 9B07 Panel Only, Lower. Switch, Start-Stop - Prior to Approx. -0- - Use #08A to Replace. Use Began Approx. -0-. Bracket, Switch Mtg. - Used with #08-90 Switch Only. Ammeter, Charge (0-0-0). Gauge. Oil Pressure (Panel Unit only) - Includes Clamp.
REF. 9B0 7 8 9 0 07B5 07B99 08-9 08-7 0P 07B8 07B A0 5 A P9 7-8 -07 9-08 0 8B0 9B08 9 A09 09B7 09-0 PARTS USI DESCRIPTION Gauge, water Temperature (Panel Unit only - Includes Clamp). Relay, Start-Disconnect. SSa.'SSSSr'SS Beset Button.» W < &» Stop Heuy and Start- H^PUot - Uftuel Sounoid Circutt, () Starter Solenoid Circuit. Relay, Stop. (Remote Operation). Block, Terminal - 5 P t o ",, H. Strip, Block barker - Markea n, o n l y Receptacle, PaneJ ^S?. only. #.. Bulb, Panel Light - Hwsea ^ Connections). Block, Terminal - PUcc^ 8 h 5. r n U r ^ s y ^ Se^r^ W i r e S Pressure Gauge - Engine Sending SeX^Water Temperature Gauge - Engine (Mounts at Engine). r.,t_o«switch, Low OUPrefure Cu oti (Optional Equipment " FIG. 0D50 0C95 0C555 0C55 0C85 Box, Control. P a paru KeyTs"! through (Unhoused Plants o n l y ) ' > 5 and (Housed Plants only! parts Key Nos., J. an ^ ^ Parts Key Nos. and (Housea (Replaces ^^cetaterpr^ouslyused). 5 508P
PARTS LIST REF. PART QUANT. USED DESCRIPTION FIG. 8 - ELECTRICAL CONTROL PANEL GROUP (AC OUTPUT) Cont. C 7 8 9 0 0P9 0-0P0 0P0 0P 0-0B5 0-0 0P8 0-0B5 0B7 0B7 0B7 A58-9 A7 A As Req. 5 A0 As Req. 0A5 As Req. 7 0A As Req. 8 08-9 0-99 0 0-78 7A 0B8 Ammeter, AC - Housed Plants only. Parts Key No. (0-50) - Replaces 0-7. Parts Key Nos., and (0-50). Parts Key No. (0-75) - Replaces 0-9. Parts Key No. 5 (0-75) - Replaces 0-9. Voltmeter, AC (0-00) Housed Plants Only - Replaces 0-. Meter, Running Time (Housed Plant only) Note: For 50 Cycle Plants, Use #0-0 Meter. Breaker, Circuit - Housed Plants only. Parts Key No.. Parts Key Nos. and. Parts Key No.. Parts Key No. 5. Parts Key No.. Transformer, Current - Housed Plants only. Parts Key Nos., and. Parts Key No.. Parts Key No. 5. Condenser, 0. mfd - Output Term. Suppression - Replaces A5. Block, Terminal - AC Output - Place. Strip, Block Marker - AC Output Block. Parts Key Nos. and (Marked Ml, M, M, M). Parts Key Nos.,, 5 and (Marked Ml, M, M, M0). Jumper, Terminal - Brass - AC Output Terminal - Parts Key Nos. and ( or required). Clamp, Current Transformer - Housed Plants only. Inside Half - () Parts Key Nos.,, 5 and ; and () Parts Key No.. Outside Half - () Parts Key Nos.,, 5 and ; and () Parts Key No.. Switch, Selector (Voltmeter-Ammeter) Housed Plants only with Parts Key Nos.,, 5 and. Resistor, Fixed - Running Time Meter (Housed Plants only with Parts Key Nos.,, 5 and.) Mounts, Rubber - Control Box to Brackets (Unhoused Plants Only). Strap, Ground - Unhoused Plants only. Plate, Meter Face - Square - For Round Faced Running Time Meter. (