Onan DJA Series Operating manual

1
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fDCSOD ^
MANUAL
AND PARTS CATALOG
SERIES
DJA
INDUSTRIAL ENGINES
0
FORMNUMBER
967-0413
Printed in U.S.A.
ISSUEDATE
5-79
(SpecA-T)

SAFETY PRECAUTIONS
Itis.recommendedthatyoureadyourenginemanualand
becomethoroughlyacquaintedwithyourequipmentbefore
youstarttheengine.
WARNING
This symbol
throughoutthis
is used
manualto
warnof possible serious personalinjury.
CAUTION
This symbol refers to possible
equipmentdamage.
Fuels, electricalequipment,batteries,exhaustgasesand
movingpartspresentpotentialhazardsthatcouldresultin
serious,personalinjury.Takecareinfollowingthese
recommendedprocedures.
SafetyCodes
•Alllocal,stateandfederalcodesshouldbeconsulted
andcomplied with.
General
•Provideappropriatefireextinguishersandinstallthem
inconvenientlocations.UseanextinguisherratedABC
byNFPA.
•Makesurethatallfastenersontheenginearesecure.
Tightensupportsandclamps,keepguardsinposition
overfans,drivingbelts,etc.
•Ifitisnecessarytomakeadjustmentswhiletheengine-
isrunning,useextremecautionwhenclosetohot
exhausts,movingparts,etc.
ProtectAgainstMovingParts
•Donotwearlooseclothinginthevicinityofmoving
parts, suchasPTOshafts,flywheels,blowers;
couplings,fans,belts,etc.
•Keepyourhandsawayfrommovingparts.
Batteries
•Beforestartingworkontheengine,,disconnect
batteriestopreventinadvertentstartingoftheengine.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesgiveoffahighlyexplosivehydrogengaswhich
canbeignitedbyflame,electricalarcingorbysmoking.
•Verifybatterypolaritybeforeconnectingbattery
cables.Connectnegativecablelast.
FuelSystem
•DONOTfillfueltankswhileengineisrunning,unless
tanksareoutsideenginecompartment.
•DONOTsmokeoruseanopenflameinthevicinityof
theengineorfueltank.Internalcombustionengine
fuelsarehighlyflammable.
•Fuellinesmustbeofsteelpiping,adequatelysecured,
and,freefromleaks.Pipingattheengineshouldbe
approvedflexibleline.Donotusecopperpipingon
flexiblelinesascopperwillworkhardenandbecome
brittleenoughtobreak.
•Besureallfuelsupplieshavea positiveshutoffvalve.
ExhaustSystem
•Exhaustproductsofanyinternalcombustionengine
aretoxicandcancauseinjury,'ordeathifinhaled.All
engineinstallations,especiallythosewithina confine,
.shouldbeequippedwithanexhaustsystemtodis-
chargegasestotheatmosphere.
•Donotuseexhaustgasestoheata compartment.
•Makesurethatyourexhaustsystemisfreeofleaks.
Ensurethatexhaustmanifoldsaresecureandarenot
warpedbyboltsunevenlytorqued.
EngineExhaustGas(CarbonMonoxide)isDeadly!
Carbonmonoxideisanodorless,colorlessgasformedby
incompletecombustionofhydrocarbonfuels.Carbon
monoxideisa dangerousgasthatcancauseun-
consciousnessandispotentiallylethal.Someofthe
symptomsorsignsofcarbonmonoxideinhalationare:
•Dizziness• Vomiting
•IntenseHeadache• MuscularTwitching
•WeaknessandSleepiness• ThrobbinginTemples
Ifyouexperienceanyoftheabovesymptoms,getoutinto
freshairimmediately.
Thebestprotectionagainstcarbonmonoxideinhalationis
aregularinspectionofthecompleteexhaustsystem.Ifyou
noticea.changeinthesoundorappearanceofexhaust
system, shut-theunitdownimmediatelyandhaveit
inspectedand'repairedatoncebya competentmechanic.
CoolingSystem
•- Coolantsunderpressurehavea higherboilingpoint
thanwater.DQNOTopena radiatorpressurecapwhile
theengineisrunning.Bleedthesystempressurefirst.
KeeptheUnitandSurroundingAreaClean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.

TABLE OF CONTENTS
TITLEPAGE
GeneralInformation2
Specifications3
DimensionsandClearances4
AssemblyTorquesandSpecialTools6
EngineTroubleshooting7
Installation8
Operation10
ServiceandMaintenance12
CoolingSystem14
FuelSystem16
GovernorSystem24
OilSystem27
StartingSystem29
FlywheelAlternator32
EngineDisassembly' 36
ControlSystem46
WiringDiagrams47
StartingGuide48
PartsCatalog49

DJASeriesengines are four cycle, vertical, air-cooled
dieselfueledengineswithoverheadvalves.The
crankcaseandcylinderareintegral.Enginesarerun
inandadjusted at thefactory.Anydamageincurredin
transitmustbecorrectedbeforeoperatingthe
engine.SeeFigure1 fora typicalmodelDJAIn-
dustrialEngine,
Normalenginespeed:range is: upto2400rpm.An
internal, constantspeed,flyball-typemechanical
governor,externally,adjustable,is standard: Optional
two-speedand:variable-speed:governorsare
available.
Wheninstructions,applytoa specificengine,model,
refertotheenginenameplatefortheModelandSpec
No. inquestion.
Throughout this, manual the flywheel end will be
calledthe front and the fuel pump side is designated
the/eff side-.. ,
TYPICAL MODELDJA
FIGURE1.' SERIESOJAINDUSTRIALENGINE
2

SPECIFICATIONS
Nominaldimensionsofengine(inches)
Height24-1/2(622mm)
Width19-1/8(486mm)
Length28-3/16(716mm)
ApproximateWeight(pounds)•..230(104kg)
NumberofCylinders•.1
Displacement(cubicinch)30(.49litre)
Bore3-1/4(82.55mm)
Stroke3-5/8(92.08mm)
HPat2400rpm(nominal)7.3(5.4kW)
CompressionRatio19:1
MainBearingsareSteel-BackedBronze,PrecisionTypefor
Replacement(quantity)2
ConnectingRodBearingsTri-MetalReplaceableYes
PistonRings(chromeplated)- 3rdCompressionRingNOTPlated
OilControl1
Compression3
HardenedChromeAlloyFacedValvesYes
HardenedChromeReplaceableValveSeats.•Yes
ValveRotator:Yes
Governor(internalflyballtype- externallyadjustable}Yes
NominalBatteryVoltage'.12
BatterySize
SAEGroupIHTwo
Amp/Hr.SAE20Hr.(nominal)105(378kC)
SolenoidShiftStarter' Yes
EnginecoolingairCFMat2400 rpm* ' 560(15.86rrvVmin)
Totalcubicfeetperminuteofairrequired613.8(17.38mVmin)
CombustionAirCFMat2400rpm21(.6mVmin)
InletVent(sq.ft.)7 (.7m2)
OutletVent(sq.in.)*64(.04m2)
GlowPlugandAirHeatertoAidStartingYes
InjectionPumpPLB
PrimaryandSecondaryFuelFiltersYes
FuelPumpLift6 ft.(1.8m)
OilPump(GearType)Yes
OilFilter(FullFlow)" Yes
OilCapacity(U.S.quarts)!2-1/2(2.4litres)
ExhaustConnection(Pipe-Tapped); 1-1/4(31.75)
PowerTake-off(inches)
ShaftLength4 (101.16mm)
ShaftDiameter1-3/4(44.45mm)
KeywayLength3 (76.2mm)
KeywayWidth3/8(9.5mm)
KeywayDepth3/16(4.76mm)
*- Pressure-cooledtypeairflow.
-Areawhenventiductisused;withoutduct,makeventaslargeaspossible.
t- Add1/2quart(.5litres)foroilfilter.
3

DIMENSIONSAND CLEARANCES
All clearances givenatroomtemperatureof70°F.
Alldimensionsin inches (metricsin parentheses) unless otherwise specified.
Minimum Maximum
CAMSHAFT
BearingJournalDiameter,Front.2.500(63.5mm)2.505(63.63mm)
BearingJournalDiameter,Rear 1.1875 (47.63mm) 1.1880 (30.18mm)
BearingClearanceLimit0.0012(.031mm)0.0037(.094mm)
EndPlay,Camshaft0.007(.18mm)0.039(.99mm)
CamTappetHoleDiameter0.7505(19.06mm)0.7515(19.09mm)
CamTappetDiameter0.7475(18.99mm)0.7480(19.00mm)
CONNECTING RODS
LargeBearingBoreDiameter2.1871(55.55mm)2.1876(55.57mm)
SmallBushingBoreDiameter1.044(26.52mm)1.045(26.54mm)
DistanceCenterLargeBearingBoretoSmall
BushingBore5.998(152.35mm)6.002(152.45mm)
Clearance,LargeBearingtoCrankshaft0.001(.03mm)0.003(.08mm)
CYLINDER
CylinderBore3-1/4(82.55mm)
CylinderDiameterLimits' 3.2495(82.54mm)3.2505(82.56mm)
CRANKSHAFT
MainBearingJournalDiameter2.2437(56.99mm)2.2445(57.01mm)
CrankshaftMainBearingClearance0.0014(.036mm)0.0052(.132mm)
ConnectingRodJournalDiameter2.0597(52.32mm)2.0605(52.34mm)
EndPlay,Crankshaft0.010(.25mm)0.015(.38mm)
PISTON
PistonClearancetoCylinderWall' 0.0055(.140mm)0.0075(.191mm)
PistonPinHoleDiameter0.9900(25.146mm)0.9903(25.153mm)
RingGrooveWidth,Top0.097(2.46mm)0.098(2.49mm)
2nd0.0965(2.45mm)0.0975(2.48mm)
3rd0.0965(2.45mm)0.0975(2.48mm)
4th0.1880(4.78mm)0.1895(4.81mm)
PISTON PIN
Length2.738(69.55mm)2.753(69.93mm)
Diameter! ' 0.9899(25.14mm)0.9901(25.15mm)
PistonClearanceThumbPushFit
ConnectingRodBushingClearance0.0002(.005mm)0.0007(.018mm)
PISTON RINGS
RingType
TopCompression
2ndCompression
3rdCompression
4thOilControl
RingWidth
Top0.0925(2.35mm)0.0935(2.37mm)
2nd, 0.0925(2.35mm)0.0935(2.37mm)
3rd0.0925(2.35mm)0.0935(2.37mm)
VALVE INTAKE(HardenedChromeAlloy Faced)
StemDiameter0.3381(8.59mm)0.3420(8.69mm)
ClearanceinGuide0.0005(.013mm)0.0025(.064mm)
SeatAngle42-degrees
ValveClearance0.011(.28mm)
4

VALVE, EXHAUST (HardenedChromeAlloy)
StemDiameter0.3405(8.65mm)0.3415(8.67mm)
ClearanceinGuide0.0025(.063mm)0.0045(.114mm)
SeatAngle45-degrees
ValveClearance0.008(.20mm)
VALVE GUIDE
Length• 1-25/32 (45.24mm)
OutsideDiameter0.4690(11.91mm)0.4695(11.93mm)
CylinderBlockBoreDiameter0.467(11.86mm)0.468(11.89mm)
InsideDiameter(afterreaming)
Exhaust0.344(8.74mm)0.345(8.76mm)
Intake0.342(8.69mm)0.343(8.71mm)
VALVE SEATS (HardenedChromeAlloy Faced)
ValveSeatBore
Diameter1.361(34.57mm)1.362(34.59mm)
Depth(fromcylinderheadface)0.433(11.00mm)0.439(11.15mm)"
SeatOutsideDiameter1.364(34.65mm)1.365(34.67mm)
SeatWidth- 3/64(1.19mm)1/16(1.59mm)
SeatAngle45-degrees
AvailableOversizes0.002(.05mm);0.005(.13mm);
0.010(.25mm);0.025(.64mm)-
VALVE SPRINGS
FreeLength1-7/8(22.23mm)
Length, ValveClosed1.528(38.81mm)
Load, ValveClosed45Ibs.(20.41kg)49Ibs.(22.23kg)
Length, ValveOpen1.214(30.84mm)
Load, ValveOpen83Ibs.(37.65kg)93Ibs.(42.18kg)
STARTING MOTOR
RotationCounterclockwise
PinionClearancetoPinionStop
(solenoidplungerbottomed)0.070(1.78mm)0.120(3.05mm)
PinionRestPosition- Distancefrompinionhousing
mountingfacetoouteredgeofpinion 1-9/32 (32.54mm) 1-15/32 (37.31mm)
ArmatureEndPlay005(.13mm)' .030(.76mm)
TestSpecifications
NoLoad10volts- 80amps(288kC)
5000rpmperMin.
StallTorque4 volts- 420amps(1512kC)
7.8ft.Ibs.perMin.(8.8N.m/min)
BrushSpringTension32-40oz.(.91kg- 1.13kg)
withnewbrushes

ASSEMBLY TORQUES
Theassemblytorquesgivenherewillassureproper
tightnesswithoutdangerofstrippingthreads.Be
carefulnottostripth reads. .Use reasonableforceonly
anda wrenchofnormallength.•
Speciallydesignedplacebolts(Figure2)donot
requirea lockwasherorgasket.Onanusesa-harden-
edflatwasherundereachboltto.preventgallingor
yieldingofbearingplatematerial..Donotattemptto
usea lockwasherwiththesebolts;itwilldefeattheir
purpose.Checkallstuds,nuts,andscrewsxrftenand
tightenasneededtokeepthemfromworkingloose.
FIGURE2.PLACEBOLT
TORQUESPECIFICATIONS FT. LBS.
ConnectingRodBolt27-29
Cover-RockerBox8-10
CylinderHeadBolt44-46
ExhaustManifoldNutsfl3-1-5
•FlywheelMountingScrew65-70
FuelPumpMountingScrews15-20
GearCaseCover18-20
GlowPlug10-15
InjectionNozzleMountingScrews....,20-21
InjectionPumpMountingScrews18-21
IntakeManifold13-15
Oil'BaseMountingScrews32-38
OilFilterHandTighten'+1/4to1/2Turn
OilPumpMountingScrews15-20
RearBearingPlate40-45
RockerArmNut*4-10
RockerArmStud35-40
t- Caution:Tightennutsevenlytoavoiddamage.
*- Thistorqueisfromfrictionbetweenthethreadsonlyandlocks
thenutinplace.Therockerarmnutsa'reforadjustingvalve
lash.
SPECIAL TOOLS
ThesetoolsareavailablefromOnantoaidserviceand
repairwork.
CrankshaftGearPullingRing420-0275
DieselNozzleTester.'.420-0184
DieselPintleNozzleCleaningTool
Set(IncludesInjectionNozzle
CenteringTool)420-0208
NozzleCenteringSleeve....-420-0321
.DeliveryValveTest'Fixturet420-0322
CombinationMainandCamBearing
Driver420-0326
•Driver,ValveSeat420-0270
OilSealGuideandDriver-
BearingPlate420-0250
GearCover420-0281
RidgeReamer420-0260
ReplacementCutterfilade
for420-0260.420-0261
"DieselCompressionTester...420-0283
ValveSeatRemover420-0311
ReplacementBladesfor420-0311420-0274
ValveGuideDriyer...:420-0300
t- Usedwithdieselnozzletester.

DefectiveFuelSystem
AirinFuelSystem
IncorrectTiming
RestrictedAirIntake- DirtyAirFilter
PoorQualityFuel
DirtyFuetFilters
OutcfFuelorShutOffClosed
WornorDamagedTransferPump,LeakingDiaphragm
FaultsInjectionPump,NozzlesorGaskets
FuelLineLeaks
WrongTimingButtoninInjectionPump
WrongThicknessPumpMountingGaskets
RunForLongPeriodsofTimeatNOLOAD
-OilSupply
DefectiveOHGauge
iOilinCrankcase
OilLeaksFromEngineBaseorConnections
LightorDilutedCrankcaseOil
LeakyOilSeals
FaultyOilBy-Pass
WornOilPump
HeavyOilorCloggedPassages
DirtyOilFilter KW.V.W.V.V.V;
•< GOVERNORSYSTEM
rDisconnectedLinkage
BindiigLinkage
:WearinLinkage
IncorrectGovernorAdjustment
HighSpringSensitivity
IncorrectlyInstalledGovernorYokeorCup
OverloadedGenerator
OLINCSYSTEM;
InsufficientCoolant
FaultyThermostat
WornWaterPumporDefectiveSeals
WaterPassagesRestricted
BlownHeadGasket
Overheating
RestrictedorTooLongWaterLines
DefectiveExpansionTankPressureCap
DirtonCoolingFins(AirCooled)
InadequateAirCirculation(AirCooled)
INTERNALENGINE
LoosePiston
LooseConnectingRodorCrankshaftBearing
Incorr-sctValveClearance
BrokenorWeakValveSpring
HighExhaustBackPressure
VaivesNotSeatingProperly
WornBearings
WornCylinderWalls,'Pistons.Rings
StickingValves
WornorDirtyValveGuides

INSTALLATION
GENERAL
Plantheinstallationcarefullytoensuremaximum
operatingefficiency.Usethismanualasa general
guide. Recommendationsinthismanualarebasedon
extensivetestsunderfavorableoperatingconditions.
Abidebypertinentlocalcodesregulatinginstallation
aridoperationofinternalcombustionengines.
Protectwallsandpartitionsthroughwhichexhaust
pipespasswitha metalshield(Figure3).
Installa suitablemufflerpreferablyasclosetothe
engineaspracticable.Pitchexhaustpipesdownward,
orprovidea condensationtrapatpointwherearisein
theexhaustsystembegins.
LOCATION
Enginelocationisdeterminedchieflybytheintended
application.Provideadequateaccessforserviceand
repair.Protecttheenginefromadverseweather.
Considerthelocationofrelatedsystems,suchas fuel,
exhaust,andventilation.
MOUNTING
Securetheenginetoa rigid, levelfoundation.Foun-
dationsmustbesturdyenoughtowithstanddistor-
tionandretainalignmentwithloadequipment.
Ifnecessarytoexceed23-degreetiltangle,consult
thefactory.Compensateforanytiltwhenchecking
crankcaseoil.
VENTILATION
Ventilationisneededtocooltheengineandsupport
combustion.Avoidrecirculationofventilatingair.See
SPECIFICATIONSsectionforairflowrequirements
andventsizes.
SINGLETHIMBLEDIAMETER12"
LARGERORDOUBLE
'•^VENTILATEDTHIMBLE
DIAMETER6"LARGER
THANEXHAUSTLINE
HOLESINEND
INNERSLEEVE
EXHAUST LINE PASSING THROUGH
|l WALL ORPARTITION
IFEXHAUSTLINEMUSTBEPITCHED
IUPWARDCONSTRUCTA TRAPOFPIPE
FITTINGSATPOINTOFRISE
AVOIDSHARPBENDS 1
DRAINCONDENSATIONTRAP
PERIODICALLY
-FIGURE3.EXHAUST
Locateventssoairflowfromtheinlettotheoutletwill
passovertheengine.Theoutletshouldbeslightly
higherthantheinlet.
Anoptionalairshuttermaybeusedintheoutletduct
tocontrolenginetemperaturebyregulatingairflow.
Airshuttersalsopreventbackflowofcoldairduring
engineshutdown.
Whenshuttersareusedbetweentheengineand
• outletvent,usea canvassectiontorestrictvibration.
EXHAUST
WARNING| Pipe9asou,sldeanyenclosure.Exhaustgas
^^n^^^^^Jispoisonous.
Exhaustpipesmustnotterminatenearinletvents.
Avoidsharpbendsbyinstallingsweeping,large
radiuselbows.Useflexibleseamlesssectiontubing
betweentheengineandanyrigidpipetorestrict
vibration. Increasetheexhaustpipeonesizeforeach
additional10-footlength.
FUEL TANKAND LINES
Installthefueltanksothattheverticaldistancefrom
bottomofthetanktothefuelpumpdoesnotexceed
sixfeet.Auxiliaryfuelpumpsareavailablewhich
provideanadditionaleight-footfuellift.
Avoidgravityfeedoffueltotheengine.Providea
siphonbreakiftankisabovepump.Whensharinga
fueltank,donotconnecttoanexistinglineata point
abovethefuelsupplylevel.
Thesedieselenginesrequirea fuelsupplylineanda
separatereturnline.Installthefuelsupplylinefrom
tanktothe 1/8-inch pipeinletinthefuelpump.
Connectthefuelreturnlinetothefitting(7/16-24
size)ontheinjectionpump(Figure4)tothetopofthe
fuelsupplytank.Useapprovedflexiblefuellinesat
theenginetoabsorbvibration.Besuretherearenoair
leaksinthesuctionline.

Donotusegalvanizedlines,fittingsorfueltanks.Carefullycleanall
fuelsystemcomponentsbeforeputtingtheengineintooperation.
Anydirtorcontaminationmaycausemajordamagetothefuel
injectionsystem.
BeginningwithSpecS,a newfuelfiltrationsystem
accommodatesbothprimaryandsecondaryfuel
filtersonacommonmountingcastingwhichisbolted
toanewlydesignedoilfill tube. Theenginecannotbe
runwitheitherfilterlooseormissing,thusensuring
properfiltrationatalltimes.
AIR
CLEANER
MANIFOLD
HEATER
SLOWPLUG
CRANKCASE
BREATHERTUBE
FUEL
RETURNLINE
FUELFILTER
SEDIMENT
BOWL
PRIMARY
FUELFILTER
INJECTION
NOZZLE
INJECTION
PUMP
SECONDARY
FUELFILTER
FIGURE4.FUELSYSTEM
BATTERY
Mountthebatteriesonawoodormetalracknearthe
engine.Aircirculationaroundthebattery is essential.
Usenumber2 batterycablesoftheproperlengthto
limitvoltagedrop.
STATOR
BATTERY CONNECTIONS
Batteriesforenginesequippedwithoptionalflywheel
alternatorsmustbenegativelygrounded.A 30amp
fuseprotectstherectifiershouldthebatterybe
connectedwithreversepolarity(Figure6).Onearly
modelswithoutfuse,destructionoftherectifierwill
result.
Connecttheremainingbatterycabletothelarger
terminalonthestartingmotorsolenoid(Figure5).
OIL DRAIN EXTENSION
Forserviceconvenience,install an oildrainextension
madefromstandardpipeandfittings,inthe 1/2-inch
pipetappedoilbasedrainhole.
STARTING
MOTOR
BATTERY
NEGATIVE
I2-V.BATTERY
FIGURE5..SOLENOIDWIRING
FUSEHOLDERWITH
30-AMPEREFUSE
ROTOR
REGULATOR-RECTIFIER
ASSEMBLY CONNECTOR
FIGURE6.FLYWHEELALTERNATOR(BEGINNINGWITHSPECT)
9

OPERATION
CRANKCASE OIL
UseanoilwiththeAPIdesignationCD/SEorCD/SD.
However,toreduceoilconsumptiontoa normallevel
intheshortesttimepossibleona neworrebuilt
engine,useCCoilforthefirstfillonly(50hours).
Thenusetherecommendedoilonly.Selectthe
correctSAEgradeoilbyreferringtothefollowing.
TEMPERATURE GRADE
Above30° F SAE30
0° F to30° F SAE10Wor5W-30
Below0oFSAE5W-30
Multigradeoilsarerecommendedfortemperaturesof
30° F andbelow,buttheyarenotrecommendedfor
temperaturesabove30oF.Whenaddingoilbetween
oilchanges,itispreferabletousethesamebrandas
inthecrankcase.Variousbrandsofoilmaynotbe
compatiblewhenmixed:together.
Iftheoilsupplyinyour local areastill has the API designationsML,
MM, MS, DC, DMand OS, use an oilwiththe DS designationwhich
haspassedtheSeries3 TestandatleastSequence1 ofthe
AutomotiveManufacturer'sMSSequenceTests.Toreduceoil
consumptiontoa normallevelIntheshortesttimeona newor
rebuiltengine,use DG or DM oil(passingthe MS SequenceTests)
forthefirstfillonly (SO hours). Thenusetherecommended oil. See
SERVICEANDMAINTENANCE seciion forsuggested oil changes.
OIL BATHAIR CLEANER
(Optional)
Usethesamegradeofoilintheaircleanerasisused
inthecrankcase.Theproperlevelismarkedontheair
cleaner.
RECOMMENDED FUEL
UseASTM2-Dor1-Dfuelwitha minimumCetane
numberof45*.Number2 dieselfuelgivesthebest
economyformostoperatingconditions;however,
useASTM1-Dfuelduringthefollowingconditions:
1. Whenambienttemperaturesarebelow32°F.
2. Duringlongperiodsoflightengine load; orno
load.
"FuelswithCetanenumbershigherthan45maybeneededin
higheraltitudesorwhenextremelylowambienttemperaturesare
encounteredto prevent, misfires.
Uselowsulfurcontentfuelhavingapourpoint(ability
tofilter)ofatleast10oFbelowthelowestexpected
temperature.Keepthefuelcleanandprotectedfrom
adverseweather.Leavesomeroomforexpansion
whenfillingthefueltank.
CAUTION Duetotheprecisetolerancesofdieselinjec-
tion systems, Itisextremelyimportant the fuel
bekept clean. Dirtinthesystemcancauseseveredamagetoboth
theinjectionpumpandtheInjectionnozzles.
INITIAL START
Checktheenginetomakesureithasbeenfilledwith
oiland fuel. Ifnecessarytoprimea dryfuelsystem,
returnthepriminglevertothedisengagedposition
afterpriming.Formoredetailedstartinginformation
seeStartingGuide,page48.
Thisunithasbeenmnandtestedforapproximatelyfourhoursat
thefactory.Additionalbreak-intimeisrequired andwillvary
dependinguponloadconditions,oilused,etc.
Run as follows:
1. Noload15-20minutes
2. One-thirdload30minutes
3.Two-thirdsload2 to3 hours
Thenregularoperationcanberesumed.Avoidlight
loadoperationduringthefollowingseveralhoursfor
bestringseatingtocontroloil.
STARTING
1. Whenstartinga coldengineinambientsabove
.550F, preheatfor20seconds.
2. Continuetoholdpreheatswitch:
a.PushthefuelsolenoidtoitsONposition.
b.PresstheSTARTswitch.
3.Releasestartswitchafterenginestartsand
reachesspeed.
4. Oilpressureshouldreadatleast20psi.Pressure
reliefvalveisnotadjustable.
Whenstartingattemperaturesbelow55°F,orunder
highhumidityconditions,refertosuggestedstarting
aidsinLowTemperaturesparagraph.
Whenrestartingengineaftershortperiodsofshut-
down, preheatingisusuallynotnecessary.
STOPPING
Disconnectasmuchloadaspracticalfromtheengine
beforeshutdown..Pushthefuelsolenoidswitchtoits
OFFposition(thisde-energizesthesolenoid,closing
thethrottle).
CAUTION Carbonintheexhaustsystemwilloccurin
dieselenginesoperatedconsistentlyatlight
loads. Occasionallyoperateengineatfullload(oraboutfive
minutesbeforestopping)tocleanouttheexhaustsystem.
10

APPLYING THE LOAD
Applytheloadfornewandreconditionedenginesin
foursteps.Wait30minutesbetweeneachstep.If
practical, allowtheengineto warm upbeforeconnec-
tinga heavy load. Trytoconnecttheloadinsteps
insteadofthefullloadatonetime.
INSPECTION
Checkforalignmentofengineand load. Misalign-
mentwillcauseexcessivevibrationandbearingwear.
Makea visualinspectionoftheentireinstallation.
PROTECTION FOR EXTENDED
OUT-OF-SERVICE PERIOD
1. Runengineuntilthoroughlywarm.
2. Draintheoilbasewhilestillwarm.Attacha
warningtagtorefillbeforeoperating.
3.Servicetheaircleaner.
4. Lubricategovernorlinkage.Protectfromdirtby
wrappingwitha cleancloth.
5.Plugexhaustoutletto keep out moistu re and dirt.
6.Cleanentireunit.Coatpartslikelytorustwith
lightgreaseoroil.
7.Providea suitablecoverfortheentireunit.
8.Disconnectbatteryandfollowstandardbattery
storage proced u res.
HIGH TEMPERATURES
1. See thatnothingobstructsairflow to and fromthe
engine.
2. Besuretheroomisproperlyventilated.
3.Keepthecoolingfins clean. Seethatairhousings
areproperlyinstalledandundamaged.
LOW TEMPERATURES
1. UsecorrectSAENo.oilfortemperature con-
ditions.Changeoilonlywhenengjneiswarm.If
anunexpectedtemperaturedropcausesan
emergency,moveenginetoa warmlocationor
applyexternallyheatedairuntildilflowsfreely
(donotuseanopenflame).-j
2. Preheatforoneminuteifthetemperatureis 55°F
orlower.Ifenginefailstostartaftbrcrankingfor
oneminute,preheatforoneminutemoreandre-
attemptthestart.Inextremecoldtemperatureit
maybenecessarytomaintainpreheatingupto2
minutesaftertheenginestartstosustainfiringor
tosmoothoutallcylinders,especiallyatnoload
orlightloads.
CAUTION Donotusepreheatformorethanone
minutebefore cranking. Thiswillhelpto
preventheaterbum-outandconservebatterypower.
3.Protectfuelagainstcondensation.
4. Keepbatteriesina well-chargedcondition.
5.Reduceroomventilation,butusecaretoavoid
overheating.
DUST ANDDIRT
1. Keepengineclean.
2. Serviceaircleanerasoftenasnecessary.
3.Changecrankcaseoilevery50operatinghours.
4. Keepoilandfuelsuppliesindust-tight con-
tainers.
5. Keep governorlinkage connections clean.
HIGH ALTITUDE
Maximumenginepowerwillbereducedabout4
percentforeach1000feetabovesealevel.
11

SERVICE AND
• Beforeengine isputin operation,check all com-
ponents for mechanicalsecurity. Ifan abnormal
condition, defectivepart, or operatingdifficulty is
detected, repair or sen/ice as required.SeeFigure 7
forserviceandmaintenance-instructions.Theengine
shouldbekeptfree of dust,dirt,andspilledoilorfuel.
Besureproperoperating-procedure is followed.
ENGINE ROUTINE CHECK CHART
WHAT TO CHECK
HOWTO CHECK PRECAUTIONS
Engine oil
Checklevel(should beat fullmark on
indicator). Add
oilas necessary to bringlevel to full
mark. Donot overfill.
Enginefuel Checklevel in tank. Seethatfuellines
are properlyconnected.
Engineventilation Checkventilatingopenings. Remove any obstructions.
Connectingcables Check
fbr properconnections.
Check for physicaldamage. Tightenconnections. Replacedamagedconnectors.
Battery Checkelectrolytelevel. Keeplevelaboveplates.
Addonlydistilledwaterasnecessary.
MAINTENANCE SCHEDULE
Usethisfactoryrecommendedmaintenance(based,
onfavorableoperatingconditions)to serve as a guide
to get long and efficientenginelife.Neglecting
routinemaintenance can result in failure or perma-
nentdamage tothe engine.
Maintenance is dividedinto two categories: (1)
OperatorMaintenance — performedbytheoperator,
and (2) CriticalMaintenance — performed by
qualifiedservicepersonnel.
OPERATOR MAINTENANCE SCHEDULE
CRITICAL MAINTENANCE SCHEDULE
MAINTENANCE
ITEMS OPERATIONALHOURS
MAINTENANCE
ITEMS 8 50 100 200 600 3000
InspectEngine X
CheckFuel x3
Gheck Oil Level X
CheckExhaustSystem • X
Check Air Cleaner xl
CleanGovernorLinkage xl
ChangeCrankcase Oil
xl-2
DrainCondensationTraps x3
CheckBattery X
Replace Oil Filter Xl
CleanCrankcaseBreather X
ChangePrimaryFuelFilter x3
ChangeSec.FuelFilter X
MAINTENANCE
ITEMS
OPERATIONALHOURS
MAINTENANCE
ITEMS 500
| 1000 2000 | 5000
CheckValveClearance x4
ReplaceSecondaryFuelFilter x3
CleanEngine X
CleanRocker BoxOil Line
Holes X
InspectValves;Grind if
Necessary X
Remove and Glean Oil Base X
CheckInjectionNozzles x6
GeneralOverhaul x5
xl - Moreoftenunderextremelydustyconditions.
x2 - CD/SD or CD/SE oil preferred. UseCCoil first 50 hours for
break-in.
x3 - Water or foreignmaterial inthe fuel can ruin the injection
system. If dailyinspectionshowswater or excessivedirt in
primaryfilterbowl,fuelhandlingandstoringfacilitiesshould
bechecked and situationcorrected.Primaryfuelfiltermust
becleaned and secondaryfuelfilterreplacedfollowing
correction of fuelcontaminationproblem.
x4 - Tightenheadbolts and adjustvalveclearanceafterfirst 50
hours ona newor overhauledengine.
x5 - Oras required.
x6 - Thisservicemust be performed by traineddieselinjection
equipmentpersonnelwithsuitabletestfacilities.Omitthis
serviceuntiltheseconditions canbemet.
For any abnormalities in operation,unusualnoises,loss of power,
overheating, etc., contactyourOnandealer.
12

BREATHER HOSE
HOSE CLAM
CAPANDVALVE CLAMP
BAFFLE
BREATHER TUBE —
CRANKCASEBREATHER
BeginningSpec R
Removehoseclamp,breatherhose,
insulatorclamp,insulatorhalves, and
breather cap clamp.Wash cap, valve
assembly, and baffle in suitablesolvent
andreinstall.
FUELFILTER
BODY
FILTER
SCREEN
GASKET
BOWL
AIR
CLEANER
(OPTIONAL)
KEEP OIL
ATTHIS
LEVE
oe o o o e o «
OOOOOOO'
OOOOOOO*
O O O 0 O 0 0 <
BREATHERTUBE
CAP
FLAPPER
VALVE
ASSEMBLY
TUBE FROM
AIR
CLEANER
:VE:L—^DILLgyiTI^J
OILFILTERCHANGE
(SeeSchedule)
Place pan under old filter and
remove by turningcounterclock-
wise. Cleanfiltermountingarea.
Install new filter; oil filtergasket
andscrewfilter on clockwise
untilgaskettouchesmounting
base, thentighten 1/2 turn.
BREATHER
TUBEBAFFLE
CRANKCASEBREATHER
Prior to Spec R
Removebreather cap. Removevalvefrom
cap. Washvalve ina suitablesolvent.
Dry and installwithperforateddisc
towardengine. If faulty,install new
valve.
ALWAYSREPLACE CAP
TIGHUY.OR Oil LEAKAGE
MAYOCCUR.
CAPANDOILLEVEL
INDICATOR
NEVER
OPERATEENGINE
WITH OILI
THIS I
AFTERWASHINGELEMENT DIP
INENGINE OILAND SQUEEZE
AS DRYAS POSSIBLE.
AIRCLEANER
ELEMENT
AINER
CONNECTOR
(Fromfuel
transferpump)
ELBOW
(Toinjection
pump)
DRAIN—PRIMARY8*
FILTER \
SECONDARY
FILTER
DRAIN
MODELSBEGINNINGWITHSPEC S
Drain water periodically asrequired from both filters and
sediment bowl. Replace primary filter every600hoursand
secondary filter every3000hours.Whenreplacing filter,
tighten screw until gaskettouches base, thentighten
screw 1 to1-1/2turns.
FIGURE 7. MAINTENANCEPROCEDURES
13

COOLING SYSTEM
Toremoveheatproducedduringoperation,engines
usea pressureair-coolingsystem.Bladesonthe
engineflywheeldrawairinthefrontoftheengine
housing, forcetheairpastthecylinderandoutthe
rightsideoftheengine.SeeFigure8.
Fromtheengineoutlet,aircanbeductedoutofthe
area. Toimproveenginetemperaturecontrol,an
optionalshutterassemblycanbeinstalledontheair
outlet.SeeFigure9.
MAINTENANCE
Withaproperlyinstalledengine,maintenanceshould
consistofcleaningtheenginecoolingarea(finson
cylinderblockandcylinderhead)atregularintervals,
normallyevery 1000 hoursbutmoreoftenunderdirty
operatingconditions.
OVERHEATING
This is sometimesdifficult to discover in an air-cooled
engine.However,thefirstsignisusuallyengine
losingspeedmomentarilyorlowenginepower.This
happensbeforetheengineseizesandresultsina
scoredpiston.
Themostprobablecausesofoverheatingaredirty
coolingsurfaces,operatingwithouttheengineair
housing, pooraircirculation,improperlubrication,
wronginjectiontimingandengineoverload.
CAUTION Theair
housing includingthedoormustbeon
whenoperatingtheengine.Overtteatingand
permanentdamagecouldresultfromaslittleasoneminuteof
operationwithoutit.
Commoninstallationproblemsleadingtoover-
heatingareasfollows:x
1. Installationwithductsizetoosmallsoairflowis
insufficient.
2. Installationinsmallroomwithnoductsand
insufficientairventilationintheroom.
3.Installationofairinletandoutletductssoair
outletfeedsbacktotheinlet.
AIR SHUTTER (Optional)
Theoptionalairshutterassemblyismountedatthe
engineairoutlet,ontherightsideoffhecylinder
shroud. A thermostaticelement(Figure10)controls
theshutterssotheycloseandlimitairflowwhenthe
airtemperaturereaches120°F.Thepowerelement
plungerbeginstomoveoutward,openingthe
shuttersuntiltheyarecompletelyopenby 140° F.
Shutteropeningtemperatureisnotadjustable,butto
assurecomplete opening, thepowerelementplunger
mustcontacttheshutterrollpinat room temperature.
Toadjustthis,loosenthepowerelementmounting
screws and slidetheassemblyuntilittouchestheroll
pinwiththeshutter.closed.
BLOWER
HOUSING
ACCESS
DOOR
AIRIN
BLOWER
WHEEL
AIRDUCT
-AND
SHUTTER
FIGURE8.COOLINGAIRFLOW FIGURE9.AIRDUCTANDSHUTTER
14

Repair
Iftheshutterwillnot open, checkthepowerelement
fordefectsorbindingoftheplunger.Besurethe
shutterdoesnotbindagainstthehousinginany
position.
Totestthepowerelement,removeitfromthe
assemblyandheatit.Whentheunitreachesabout
120oF, theplungershouldstarttomoveout.Total
movementshouldbeatleast1/5-inch.Donot
overheat.
Iftheunitwillnotclose,checkfora weakreturn
spring, bindinginthenylonbearingsordirtinthe
powerelementplunger.Ifthenylonbearingsare
wornor bind, replace them. Removetheshuttersand
pulloutthestubshaft.Pushouttheoldandpushin
newbearingsfromtheinsideoftheshutterhousing.
Thelargebearingsurfaceserves as a spacerbushing
soitmustbeontheinsideofthehousing.The
shuttersshouldbeadjustedtoobtainanendthrust
clearanceofnotmorethan1/32-inch.
HIGH TEMPERATURE CUT-OFF
Whenoptionalautomaticairdischargeshutteris
used, itisrecommendedthattheshutterincludea
hightemperaturecut-off switch. Thisswitchprotects
theengineifshutterfailstoopen.Theswitchisin
serieswiththegovernor solenoid. Switchisnormally
closedandopensatabout 240° F. Whenit opens, the
solenoidisde-energized,stoppingtheunit.The
switchclosesagainatabout1950F.
LATEMODELS
UPPERSHUTTER
ACTUATINGROD
SHUTTERS
EARLY MODELS
SHUTTER
ACTUATING
ADJUST THE VERNATHERM
POWER ELEMENT TOREST
ONTHEROLLPIN WITH
SHUTTER CLOSED AT AMBIENT
TEMPERATURE
VERNATHERM
POWER ELEMENT
LOWER SHUTTER
ACTUATING ROD
ADJUST THE VERNATHERM
POWER ELEMENT TOREST
ONTHEROLLPIN WITH
SHUTTER CLOSED AT AMBIENT
TEMPERATURE
VERNATHERM BRACKET
ADJUSTINGAND MOUNTING
SCREWS INSLOTTED HOLES
FIGURE 10. AIR SHUTTER
15

FUEL SYSTEM
Thedieselfuelsystemprovidesa means of filtering,
transportinganddeliveringfuel in afinespraytothe
enginecylinder at thecorrecttime for ignition. The
systemconsists of a primaryfuelfilter,fueltransfer
pump, secondaryfuelfilter,injectionpump and an
injectionnozzle.SeeFigure11.
Thediaphragmfueltransferpumpwhichoperates
directly off the enginecamshaft,drawsfuelfrom a
supplytankanddelivers it throughtwofilterstothe
injectionpump.Theinjectionpumpmetersfuel and
delivers it,at highpressuretotheinjectionnozzle at
thecorrecttime for ignition.
Theinjectionnozzleopens at a. set fuelpressure,
deliveringfuel in a finespray, to theprecombustion
chamber for ignition. The nozzleremainsopen,
deliveringfuel as longas,thefuelpressureremains
abovethecriticalpoint.
Extra fuel isbledoffafter each injectioncycleby a fuel
returnlinefromthenozzle.Anadaptercombinesthe
returnfuelwith the flow-throughfuelfrom the
injectionpump. A returnlineconnected.atthispoint,
returns the combinedfuelback to the fuelsupply
tank.
CAUTION^
D,rtln,he'uel 8y8,em l8a
dieselengine's
worstenemy. It Isoneofthemajorcauses of
dieselengine failure. Even a tiny piece ofdirt in theInjectionsystem
maystopyourunit When, opening any partof.thefuelsystem
beyondthesecondaryfuelfilter,placeallpartsIn a pan of clean
dieselfuel as they are removed. Before installingnewor used parts,
flushthemthoroughlyandInstallwhilestillwet.
MAINTENANCE
Inaddition to regularserviceperiods,change the
secondaryfuelfiltercartridge if the engineshows
signs of starvingfromlack of fuel.. Remove the
secondaryfilter by removing the largecapscrew in
thecenterofthefiltercover.Use care when replacing
thefiltercartridge to avoidgettingdirtinto the
injectionpumppassages.
Whenreplacing or cleaningfilters,bleed the fuel
system. Do this by opening theair bleedscrew
located on top of the secondaryfilterremoval cap
screw.Operatethehandpriminglever on thetransfer
pumpuntilno air bubblesflowfromthebleedscrew
hole, thentightenthe bleed screw.Returnthepriming
lever toits originalposition.SeeFigure 12.
Ifthetransferpumpcamlobe is on thehigh side, thepriminglever
will not operatethepump.Tumtheengineonerevolutionbefore
operatingthepriminglever.
AIR
CLEANER
MANIFOLD
HEATER
6LOWPLUS
CRANKCASE
BREATHERTUBE
FUEL
RETURNLINE
FUELFILTER
SEDIMENT
BOWL
PRIMARY
FUELFILTER
INJECTION
NOZZLE
INJECTION-
PUMP '
SECONDARY
FUELFILTER
WORK TRANSFE R PUMP
PRIMING LEVER To FILU
FILTER
NOTE:IF PRIMING LEVER
DOES NOT ENGAGECRANK
ENGINE ONE REVOLUTION.
REMOVE BLEEDPLUG FROM
TOP OF FUEL FILTER
ALLOW FUEL TOFLOW
FROM BLEEDER HOLE
UNTIL NO A::RBUBBLES
APPEAR.
FIGURE11.DIESELFUELSYSTEM(BEGINNING
WITHSPEC S)
FIGURE 12. BLEEDINGFUELSYSTEM
(PRIORTOSPECS)
16

FUEL TRANSFER PUMP
Thetransferpumpislocatedontheleftsideofthe
engine.Iffueldoesnotreachthesecondaryfilter,
makethefollowingchecksbeforeremovingthe
pump.
1. Checkthefueltankandseethattheshutoffvalve
isopen.
2. Removethefuellinefromthetransferpump
outletandworktheprimingleveronthepump.
Fuelshouldspurtoutofthepump.Ifnot,remove
thepumpforrepairorreplacement.
Testing
Ifthetransferpumpdelivers fuel, testitwitha
pressuregaugeormanometer.Performthesetests
beforeremovingthepumpfromtheengine.Remove
thepumpoutletandinstallthepressuregauge.See
Figure15.
Testthevalvesanddiaphragmbyoperatingthe
primerleverafewtimesandwatchingthepressure.It
shouldnotdropoffrapidlyafterpriminghasstopped.
Nextruntheengineatgovernedspeedonfuel
providedbygravityfeedandmeasurethefuelpump
pressuredeveloped.Pressureshouldbebetween5
and6 psiwiththegauge16inchesabovethefuel
pump.
Alowpressurereadingindicatesextremewearinone
partorsomewear in allparts,andthepumpshouldbe
overhauledorreplaced.Ifthereadingisabove
maximum,thediaphragmisprobablytootightorthe
diaphragmspringtoostrong.Thiscanalsobecaused
byfuelseepingunderthediaphragmretainernutand
betweenthediaphragmlayers,causinga bulgeinthe
diaphragm.Overhaulthepumpandreplacethe
defectiveparts.SeeFigure16.
Lowpressurewithlittleornopressureleakafter
pumpingstopsindicatesa weakorbrokenspringor
wornlinkageandinmostcasesthepumpshouldbe
replaced.
Repair
Transferpumpfailureisusuallyduetoa leaking
diaphragm,valveorvalvegasket.A kitisavailablefor
replacementofvariousparts.Becausetheextentof
wearcannotbedetectedbytheeye,replaceallparts
inthekit.Ifthediaphragmisbrokenorleaks,check
fordilutedcrankcaseoilandreplace.
Occasionally,failureisduetoabrokenorweakspring
orwearinthelinkage.Inthiscase,replacetheworn
partsorinstalla newpump.Obtainreplacementparts
orinstalla newpump.Obtainreplacementpartsother
thantherepairkitfromanoriginalequipmentparts
distributor.
UPPERPUMPBODY
GASKET
VALVEANDCAGE
DIAPHRAGM
ROCKERARM
SPRING
DIAPHRAGM
SPRING
LOWER
PUMPBODY ftV ROCKERARMAND
7LINKASSEMBLY
t„ ROCKER
>,^$ARMPIN
FIGURE13.EXPLODEDVIEWOFJ-SERIESPUMP
Fuel PumpRemoval
Disassembly
1. Afterthepumpisremovedfromtheeng ine, scribe
alineontheflangesoftheupperandlowerpump
bodiestoassurecorrectpositioningwhen
reassembling.
2. Removethesecuringscrewsandseparatethe
upperandlowerpumpbodies(Figure13).
3.Torelease thepumpdiaphragm,pressdownon
thebaseofthediaphragmattheedgefarthest
fromthepumpmountingflange.Withoutreleas-
ingthisedge,pressdownontheoppositeedge.
Thisactionwillunhookthediaphragmactuating
rodfromtherockerarmlink(Figure14).
4. Withtheaidofa pliersorscrewdriver,pushand
tiptherockerarmreturnspringoffthecatchon
therockerarmandremovefrompump.
5.Cleanandinspectallpumpcomponentsnot
includedintherepairkit.Ifdamageisapparent,
replacethepump.
ThevalveandcageassembliesonIheJ seriespumpare
permanentlymountedintheupperbodyofthepump.Ifthe
assembliesaredamagedornoticeablyworn,theentirepump
mustbereplaced.
17

PRESSDOWNONDIAPHRAGMBASEHERE
DIAPHRAGM
ROCKERARM
STEPONE
CONTINUETOPRESSHERE
PRESSDOWNHERETOTIPDIAPHRAGM
RODOFFROCKERARMLINK
DIAPHRAGM
ROCKERARM
STEPTWO
FIGURE14.REMOVALOFJ-SERIESDIAPHRAGMASSEMBLY
Assembly
1. Lubricatethediaphragmactuatingrodandinstall
thenewdiaphragminthepump.Reversethe
procedureusedforremoval,rollingbackthe
diaphragmfabrictoviewtherockerarmlink
(Figure14).Holdthepumpbodyupside-downso
thattheweightofthelinkwillkeepitwithinreach
ofthediaphragmactuatingrod.
2. Installthenewrockerarmreturnspring..
3.Placetheupperandlowerbodiesofthepump
,togetherwiththescribemarksaligned.Startthe
sixsecuringscrews,makingsuretheydonot
chewintothediaphragmfabric.Leavethescrews
2or3 turnsloose.
4. Operatetherockerarmseveraltimestofullyflex
thenewdiaphragm.Whileholdingtherockerarm
fullyflexed,tightenthesecuringscrews.
Failuretofullyflextherockerarmwhile
tighteningthepumpbodiestogetherwill
resultinexcessivepumppressureandpossibleengine
floodingorpumpdiaphragmfailure.
CAUTION
NOZZLE
Theinjectionnozzleistheconventionalinward
openingpintletypewithadjustableopeningpressure.
Itisfactoryadjustedtoopenat1900to1950 psi. After
severalhundredhoursofoperationthenozzle
pressurewilldecreasetoapproximately1750psi.Do
notdisassemblethenozzleoradjustnozzlepressure
withoutpropertestequipment.A nozzlepressure
testerisessentialtodothiswork.
FUELPUMP1
OUTLET
FIGURE15.FUELPRESSUREGAUGE
Inspection
Toinspectthenozzlespraypattern,removethe
nozzlefromthecylinderhead.Cranktheengine,let
thenozzlesprayintotheairandwatchthepattern.
Thesprayshouldbeconeshapedwitha solid
appearingcentersurroundedbycloudlikefogin
whichthesprayisevenlyatomized.SeeFigure 17. An
apparentchatteringofthenozzleisnormal.
Ifstreamer'sarevisible,thepatternisbadlydistorted
orthenozzledripsbeforeitreachesopening
pressure,itisdefectiveandmustbecleanedor
replaced.
WARNING
seriousinfection.
Donotletthenozzlesprayagainstyour skin.
Thefuelcanpenetratefleshandcausea
Adjustment
Toadjusttheopeningpressure,removethenozzle
fromtheengine.Removethecapnutoverthe
adjustingscrewofthenozzleandinstallthenozzleon
astaticfuelnozzletestingfixture(maybepurchased
fromOnan).Followingthetesterinstructions,adjust
theopeningpressureto1750psibyturningthe
adjustingscrew.SeeFigure18.Clockwiseincreases
thepressureandcounterclockwisedecreasesit.Do
nottryto adj ustthepressurewithout a testi ng fixtu re.
18