Onan DJBA Series Instruction Manual

OPERATOR'S/SERVICE
MANUAL
AND PARTS CATALO i
SERIES
DJBA
INDUSTRIAL ENGINES
967-0423
ISSUEDATE
6-79
(SPECP-W)
Printedin U.S.A.

SAFETY PRECAUTIONS
• Itisrecommendedthatyouread'yourenginemanualand
becomethoroughlyacquaintedwithyourequipmentbefore
youstarttheengine.
WARNING
J
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.
Safety Codes
•Alllocal,stateandfederalcodesshouldbeconsulted
andcomplied with.
General
•Provideappropriatefireextinguishersandinstallthem
inconvenientlocations.UseanextinguisherratedABC
-byNFPA.
•Makesurethatallfastenersontheenginearesecure.
Tightensupportsandclamps,keepguardsinposition
overfans,drivingbelts,etc.
•Ifitisnecessarytomakeadjustmentswhiletheengine
isrunning,useextremecautionwhenclosetohot
exhausts,movingparts,etc.
ProtectAgainst Moving Parts
•Donotwearlooseclothinginthevicinityofmoving
parts, suchasPTOshafts,flywheels,blowers,
couplings,fans,belts,etc.
• Keep your hands away from movingparts.
Batteries
•Beforestartingworkontheengine,disconnect
batteriestopreventinadvertentstartingoftheengine.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesgiveoff a highlyexplosivehydrogengaswhich
canbeignitedbyflame,electricalarcingorbysmoking.
•Verifybatterypolaritybeforeconnecting
cables.Connectnegativecablelast.
Fuel System
battery
DONOTfillfueltankswhileengineisrunning,unless
tanksareoutsideenginecompartment.
•DONOTsmokeor'useanopenflameinthevicinityof
theengineorfueltank.Intemalcombustionengine
fuelsarehighlyflammable.
'• Fuellinesmustbeofsteelpiping,adequatelysecured,
andfreefromleaks.Pipingattheengineshouldbe
-approvedflexiblejine.Donotusecopperpipingon
flexiblelinesascopperwillworkhardenandbecome
brittleenoughtobreak.
•Be sure allfuel supplies havea positiveshutoffvalve.
Exhaust System
•Exhaustproductsofanyinternalcombustion.engine
aretoxicandcancauseinjury,ordeathifinhaled.All
engineinstallations,especiallythosewithina confine,
shouldbeequippedwithanexhaustsystemtodis-
chargegasestotheatmosphere.
•<*
•Donotuseexhaustgasestoheata compartment.
•Makesurethatyourexhaustsystemisfreeofleaks.
Ensurethatexhaustmanifoldsaresecureandarenot
warpedbyboltsunevenlytorqued.
Engine Exhaust Gas(Carbon Monoxide) 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, shuttheunitdownimmediatelyandhaveit
inspectedandrepairedatoncebya competentmechanic.
Cooling System
•Coolantsunderpressurehavea higherboilingpoint
thanwater.DONOTopena radiatorpressurecapwhile
theengineisrunning.Bleedthesystempressurefirst.
Keep theUnitandSurroundingArea Clean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.

TABLE OFCONTENTS
TITLE PAGE
General Information 2
Specifications3
DimensionsandClearances4
AssemblyTorquesandSpecialTools6
DieselEngineTroubleshooting7
Installation8
Operation 10
Service and Maintenance 12
CoolingSystem14
FuelSystem16
GovernorSystem24
OilSystem27
StartingSystem30
Flywheel Alternator 34
Exhaust System37
EngineDisassembly38
ControlSystem48
Special Equipment50
DieselStartingGuide51
Wiring Diagrams52
PartsCatalog55

GENERAL INFORMATION
TheseinstructionsapplytotheDJBAindustrial
engine.Therearemanyoptionswhichcanbeadded
tothisengine.Identifyyourparticularmodelby
referringtotheunitnameplate.
HowtointerpretMODELand SPEC NO.
DJBA - MS/ 375W
1
3 4
1. Factorycodeforgeneralidentificationpurposes.
2. SpecificType:
MS- ELECTRICstartingwithstubshaft.
3.Factorycodeforoptionalequipmentsupplied.
4. Specification(SpecLetter)advanceswithfactory
productionmodification.
TYPICALDJBA ENGINE

SPECIFICATIONS
(All values givenin inches unless otherwisespecified.)
Dimensions
Height26(660mm)
Width18-3/8(467mm)
Length23-5/16(592mm)
Weight288(131kg)
NumberofCylinders2
Displacement(cu.in.)60(.98litre)
Bore3-1/4 (82.55 mm)
Stroke3-5/8(92.08mm)
H.P.at2400rpm(nominal)14.6(10.9kW)
CompressionRatio19:1
MainBearingsareLeadedBronze,PrecisionTypeforReplacement(Qty.) '. 2
ConnectingRodBearingsTri-MetalReplaceableYes
PistonRings(chromeplated)
OilControl1
Compression3
HardenedChrome- CobaltAlloyFacedValvesYes
HardenedChrome- CobaltAlloyReplaceableValveSeats'. Yes
ValveRotator, Yes
Governor(internalflyballtype- externallyadjustable)Yes
GovernorRegulation% 5
NominalBatteryVoltage-.12
BatterySize
SAEGroupIH(numberused)Two
Amp/Hr.SAE20hr.Minimum105(378kC)
SolenoidShiftStarterYes
EnginecoolingairCFMat1800rpm£ 590
Totalcu.ft.permin.ofairrequired613.8(17.38mVmin)
CombustionAir(cfm)* 42(.3rrvVmin)
CoolingAir(cfm)* 850(16.71mVmin)
InletVent(sq.ft.)7 (.7m2)
OutletVent(sq.in.)**80(.05m2)
AirCleaner(std.).'OilWetted
GlowPlugsandAirHeatertoAidStartingYes
InjectionPump(AmericanBoschType)PSU
PrimaryandSecondaryFuelFiltersYes
FuelPumpLift(Feet,maximum)6 (1.83m)
OilPump(GearType)Yes
Oil Filter (full flow) \es
OilCapacity(U.S.quarts)££3-I/3(3.3ntres)
ExhaustConnections(PipeTapped)1-1/4(31.75mm)
PowerTake-off(inches)
ShaftLength4 (101.I6mm)
ShaftDiameterI-3/4(44.45mm)
KeywayLength3 (76.2mm)
KeywayWidth3/8(9.5mm)
KeywayDepth> 3/16(4.76mm)
*- Airrequirementsat2400rpm.
**- Areawhenventiductisused;withoutduct,makeventaslargeaspossible.
£- Pressure-cooledtypeairflow.
££- Includes1/2quartfor(.47litres)foroilfilter.
3

DIMENSIONSAND CLEARANCES
(All values givenin inches unless otherwisespecified.)
MINIMUM MAXIMUM
CAMSHAFT
BearingJournalDiameter,Front.2.500(63.5mm)2.505(63.63mm)
BearingJournalDiameter,Rear•. 1.1875 (47.63mm) 1.1880 (30.18mm)
BearingClearanceLimit.0012(.031mm).0037(.094mm)
EndPlay,Camshaft.007(.18mm).039(.99mm)
CamTappetHoleDiameter8755(22.24mm).8765(22.26mm)
CamTappetDiameter8725(22.16mm).8730(22.17mm)
CONNECTING RODS
LargeBearingBoreDiameter2.1871(55.55mm)2.1876(55.57mm)
SmallBushingBoreDiameter1.044(26.52mm)1.045(26.54mm)
DistanceCenterLargeBearing
BoretoSmallBushingBore5.998(152.35mm)6.002(152.45mm)
Clearance,LargeBearingtoCrankshaft.0010(.025mm).0033(.084mm)
CRANKSHAFT
MainBearingJournalDiameter• 2.2437(56.99mm)2.2445(57.01mm)
CrankshaftMainBearingClearance.0020(.051mm).0033(.084mm)
ConnectingRodJournalDiameter2.0597.(52.32mm)2.0605(52.34mm)
EndPlay,Crankshaft.010(.25mm).015(.38mm).
CYLINDER
CylinderBore. 3-1/4(82.55mm)
CylinderDiameterLimits: 3.2495(82.54mm)3.2505(82.56mm)
PISTON
PistonClearancetoCylinderWall.0055(.140mm).0075(.191mm)
PistonPinHoleDiameter99005(25.15mm).99025(25.15mm)
RingGrooveWidth,Top.097(2.46mm).098(2.49mm)
RingGrooveWidth,2nd.0965(2.45mm).0975(2.48mm)
RingGrooveWidth,3rd0965(2.45mm).0975(2.48mm)
RingGrooveWidth,4th.1880(4.78mm).1895(4.81mm)
RingSideClearance.002(.051mm).006(.152mm)
PISTON PIN
Length: *.' 2.738(69.55mm.)2.753(69.93mm)
Diameter.-9899(25.14mm).9901(25.15mm)
PistomClearance@ 70°F " 00005 (.0013 mm).00025 (.0064 mm)
ConnectingRodBushingClearance.0002(.005mm).0007(.018mm)
PISTON RINGS
RingType
Topi Compression
2ndCompression
3rd• Compression
4thOilControl
RingWidth
Top.".0925(2.35mm).0935(2.37mm)
2nd0925(2.35mm).0935(2.37mm)
3rd• .0925(2.35mm).0935(2.37mm)
RingGapinCylinder.010(.25mm)
STARTING MOTOR
RotationCounterclockwise
PinionClearancetoPinionStop
(SolenoidPlungerBottomed).070(1.78mm).120(3.05mm)
PinionRestPosition- Distancefrom
.PinionHousingMountingFacetoOuterEdge
ofPinion 1-9/32 (32.54mm) 1-15/32 (37.31mm)
4

ArmatureEndPlay
TestSpecifications
NoLoad
StallTorque
BrushSpringTension
VALVE, INTAKE(Cobalt-ChromeAlloy)
StemDiameter
ClearanceinGuide
FaceAngle.',
ValveClearance(cold)
VALVE, EXHAUST (Cobalt-ChromeAlloy)
StemDiameter
ClearanceinGuide
Face Angle
ValveClearance(cold)
VALVE GUIDE
Length
OutsideDiameter
CylinderHeadBoreDiameter
InsideDiameter(afterReaming)
Exhaust
Intake—
VALVESEATS (Stellite)
ValveSeatBore
Diameter
Depth(fromCylinderHeadFace)
SeatOutsideDiameter
SeatWidth
SeatAngle
VALVE SPRINGS
FreeLength
Length, ValveClosed:
Load, ValveClosed
LengthValveOpen
Load, ValveOpen
VALVELIFTERS
LifterDiameter
LifterBore
OIL PUMP BYPASSVALVE
PlungerDiameter
SpringFreeLength
SpringTension(at 1-3/16 inchcompressed)
.005(.13mm) .030(.76mm)
10Volt-80Amps
5000rpmMinimum
4Volt- 420Amps
7.8ft.Ibs.Min.(10.6N«m)
32- 40oz.withnewbrushes
(.91kg-1.13kg)
.3405(8.650mm)
.0015(.038mm) 42°
.3410(8.66mm)
.0030(.076mm)
.009Intake(.229mm)
.3405(8.65mm).3415(8.67mm)
.0030(.076mm).0050(.127mm)
45°
.007Exhaust(.178mm)
1-25/32 (45.24mm)
.4690(11.91mm).4695(11.93mm)
.467(11.86mm)
.3445(8:75mm)
,3425(8.70mm)
1.361(34.57mm)
.433(11.00mm)
1.364(34.65mm)
3/64(1.19mm) 45°
.468(11.89mm)
.3455(8.78mm)
.3435(8.73mm)
1.362(34.60mm)
.439(11.15mm)
1.365(34.67mm)
1/16(1.59mm)
1-7/8(47.63mm)
1.528(38.81mm)
45(20.41kg)49Ibs.(22.23kg)
1.182(30.02mm)
87Ibs.(39.46mm)
.8725(22.16mm)
.8755(22.24mm)
97Ibs.(42.1848)
.8730(22.17mm)
.8765(22.26mm)
.3365(8.55mm).3380(8.59mm)
2-1/4(57.15mm)2-3/8(60.33mm)
2.225Ib.+ .11Ib.
(1.01kg+ .05kg)

ASSEMBLY TORQUES AND SPECIAL TOOLS
Theassemblytorquesgivenherewillassureproper
tightnesswithoutclangerofstrippingthreads.Use
reasonableforceonlyandawrenchofnormallength.
SpeciallydesignedPlaceBolts(Figure1)donot
requirealockwasherorgasket.Donotattempttouse
alockwasherwiththesebolts,itwilldefeattheir
purpose.Checkallstuds,nutsandscrewsoftenand
tightenasneededtokeepthemfromworkingloose.
RECESSED
UNDERHEAD
SPECIALTOOLSANDEQUIPMENT
ThesetoolsareavailablefromOnantoaidserviceand
repairwork.
CrankshaftGearPullingRing420-0275
DieselNozzleTester' 420-0184
DieselPintleNozzleCleaningToolSet
(IncludesInjectionNozzileCentering
Tool)420-0208
NozzleCenteringSleeve420-0321
DeliveryValveTestFixturet420-0322
CombinationMainandCamBearing
driver420-0326
Driver,ValveSeat* .420-0270
OilSealGuideandDriver
BearingPlate420-0250
GearCover420-0281
RidgeReamer420-0260
ReplacementCutterBlade
for420-0260420-0261
DieselCompressionTester420-0283
ValveSeatRemover420-0311
ReplacementBladesfor420-0311420-0274
ValveGuideDriver420-0327
FIGURE1.SPECIALPLACEBOLT t- Usedwithdieselnozzletester.
TORQUESPECIFICATIONSLB-FT
ConnectingRodBolt...27-29
Cover-RockerBox8-10
CylinderHeadBolt44-46
ExhaustManifoldNuts13-15**
FlywheelMountingScrew65-70
FuelPumpMountingScrews15-20
GearCaseCover18-20
GlowPlug10-15
InjectionNozzleMountingScrews......20-21
InjectionPumpMountingScrews15-16
IntakeManifold13-15
OilBaseMountingScrews45-50
OilFilterHandTight+1/4to 1/2Turn
OilPumpMountingScrews15-20
RearBearingPlate40-45
RockerArmNut4-10*
RockerArmStud35-40
-Thistorqueisfromfrictionbetweenthethreadsonly
andlocksthenutsinplace.Therockerarmnuts
areforadjustingvalve lash.
-Caution:Tightennutsevenlytoavoidmanifold
damage.

o
z
Ui O
zo
o5
2o
5£
TROUBLE -E
HardStartingorFailuretoStart
ExcessiveOilConsumptionLightBlueSmokyExh
ExcessiveOilConsumotionNoSmokeIncrease
ExcessiveFuelConsumptionBlackSmokyExhaust"
MechanicalKnocks
^Engme^sinr^^^^
^o^^neme^ower^
CoolingTemperatureTooHigh
bxcessiveFuelConsunption
FuelKnocks
bpeedTooMigh
SpeedTooLow
HuntingCondition
PoorSensitivity
NoGovernorControl
DilutedOil
CrankcaseSludge UUUHU
LowOilPressure
HighOilPressure
StarterMotorDoesn'tTurn
SlowStarterSpeed
Ttarte^Won^Pngag^^TywTieeF
PoorCompression
ValveBreakage
ValveBurning
PistonandCylinderandRingWear
WornConnectingRod,BushingsandBearings
StickingValves

INSTALLATION
GENERAL
Theinitialinstallationisveryimportant.Planit
carefullytoensuremaximumoperatingefficiency.
Usethismanualasa generalguide.Recommen-
dationsinthismanualarebasedonextensivetests
underfavorableoperatingconditions.Abidebyperti-
nentlocalcodesregulatingtheinstallationand
operationofinternalcombustionengines.
LOCATION
Enginelocationisdeterminedchieflybytheintended
application.Provideadequateaccessforserviceand
repair.Protectthetheehginefromadverseweather.
Considerthelocationofrelatedsystems,suchas fuel,
exhaustandventilation.
Pipeexhaustgasoutsideanyenclosure.Exhaust
pipesmustnotterminatenearinlet vents. Avoidsharp
bends;usesweeping,largeradiuselbows.Usea
sectionofseamless,flexibletubingbetweenthe
engineandanyrigidpipetorestrictvibration.In-
creaseexhaustpipeonesizeforeachadditional10
feetinlength.
Usea metalshieldtoprotectwallsandpartitions
throughwhichexhaustpipespass.SeeFigure2.
Installa suitablemufflerasclosetotheengineas
practicable.Pitchexhaustpipesdownward,or
providea condensationtrapatpointwherea risein
theexhaustsystembegins.'
MOUNTING
Securetheenginetoa rigid, levelfoundation.Foun-
dationsmustbesturdyenoughtowithstanddistor-
tionandtoretainalignmentwithcomplementary
equipment.
Ifnecessarytoexceed23°tiltangle,consultfactory
formaximums.Compensateforanytiltwhencheck-
ingcrankcaseoil.
SINGLETHIMBLEDIAMETER12"
LARGERORDOUBLE
VENTILATEDTHIMBLE
DIAMETER6"LARGER
THANEXHAUSTLINE
HOLESINEND
INNERSLEEVE
VENTILATION
Goodventilationisneededtocooltheengineandto
supportcombustion.Avoidrecirculationof ven-
tilatingair.SeeSpecificationsforairflowre-
quirementsandventsizes.
Locateventssotheflowofairfromtheinlettothe
outletwillpassovertheengine.Theoutletshouldbe
slightlyhigherthantheinlet.
Anoptionalairshuttermaybeusedintheoutletduct
tocontrolengine tem rperaturebyregulatingairflow.
Airshuttersalsopreventback-flowofcoldairduring
engineshut-down.
Whenusingventiductsbetweentheengineandoutlet
vent,provideasectionoffcanvastorestrictvibration.
EXHAUST
WARNING Pipeexhaustgasesoutofanyenclosure.
Inhalationofexhaustgasescanresultin
seriouspersonalinjury.
FIGURE2.EXHAUSTLINEPASSINGTHROUGH
WALLORPARTITION
FUEL TANKAND LINES
Wherea separatefueltankisused,installsothe
verticaldistancefrombottomofthetanktothefuel
pumpdoesnotexceed6 feet. Auxiliaryfuelpumpsare
availabletoprovideanadditional8 footlift.
Avoidgravityfeedoffueltotheengine.Providea
siphonbreakiftankisabovepump.Whensharinga
fueltank,donotconnecttoanexistinglineata point
abovethe.fuelsupplylevel.
Thesedieselenginesrequirea fuelsupplylineanda
separatereturnline.Installthefuelsupplylinefrom
tanktothe1/8"pipeinletinthefuelpump.Connect
fuelreturnlinetofittingatinjectionpump,seeFigure
3.Useapprovedflexiblefuellinesattheengineto
absorbvibration..Besuretherearenoairleaksinthe
suctionline.Installa shut-offvalveinthetankfor
serviceconvenience.

CONNECTFUEL
RETURNLINE.
HERE(FLEXIBLE
LINE)
FIGURE3.FUELRETURNLINES
BATTERY
Mountthebatteryona woodormetalracknearthe
engine.Aircirculationaroundthebatteryisessential.
Use#2batterycablesoftheproperlengthtolimit
voltagedrop.
PriortoSpecV only:Ifbatterypositivemustbe
groundedtoagreewithrelatedequipment,reverse
thetwoconnectionsontherectifier(Figure5).
Connecttheremainingleadfroma suitableDC
sourcetothelargerterminalonthestartingmotor
solenoid(Figure4).
OIL DRAIN EXTENSION
Forserviceconvenience,installanoildrainextension
madefromstandardpipeandfittings,inthe1/2"pipe
tappedoildrainholeintheoilbase.
STARTING
MOTOR
BATTERY
NEGATIVE
12-V. BATTERY
BATTERY CONNECTIONS
Connectthebatterycablemarked"POS."tothe
batterypositive(+)terminal(Figure4).Connectthe
unmarkedterminaltothebatterynegative(-)ter-
minal. Alwayskeepcableconnectionstightand
clean. A fuseprotectsthechargingsystemifthe
batteryisconnectedwithreversepolarity.
FIGURE4.STARTINGSYSTEM
BLACK
TO
GROUND
A857
XL
H—M
RED
TOBATTERY
CHARGING
CIRCUIT
FIGURE5. NEGATIVEGROUNDSYSTEM(PRIORTOSPECV ONLY)
9

OPERATION
CRANKCASE OIL
UseanoilwiththeAPIdesignationCD/SEorCD/SD.
However,toreduceoilconsumptiontoa normallevel
intheshortesttimepossibleona neworrebuilt
engine,useCCoilforthefirstfillonly(50hours).
Thenusetherecommendedoilonly.Selectthe
correctSAEgradeoilbyreferringtothefollowing.
Above30°F
0°F to30°F
Below0°F
SAE30
SAE10Wor5W-30
SAE5W-30
Multigradeoilsarerecommendedfortemperatureof
30°F andbelow,buttheyarenotrecommendedfor
temperaturesabove30°F.Whenaddingoilbetween
oilchanges,itispreferabletousethesamebrandas
inthecrankcase.Variousbrandsofoilmaynotbe
compatiblewhenmixedtogether.
Iftheoilsupplyinyourlocalareastillhasthe API designationsML,
MM, MS,DG,DMandDS,useanoilwiththeDSdesignationwhich
haspassedtheSeries3 TestandatleastSequenceI ofthe
AutomotiveManufacturer'sMSSequenceTests.Toreduceoil
consumptiontoa normallevelIntheshortesttimeona newor
rebuiltengine,useDGorDMoil(passingtheMSSequenceTests)
forthefirstfillonly(50hours).Thenusetherecommended oil. See
PERIODICMAINTENANCEforsuggestedoilchanges.
OIL BATHAIR CLEANER (Optional)
Usethesamegradeofoilintheaircleanerasusedin
thecrankcase.Theproperlevelismarkedontheair
cleaner.
Recommended Fuel
UseASTM2-Dor1-Dfuelwitha minimumCetane
numberof45*.Number2 dieselfuelgivesthebest
economyformostoperatingconditions;however,
useASTM1-Dfuelduringthefollowingconditions:
1. Whenambienttemperaturesarebelow32°F
(0°C);
2. Duringlongperiodsoflightengine load; orno
load.
'NOTE: FuelswithCetanenumbershigherthan45maybeneeded
inhigheraltitudesorwhenextremelylowambienttemperaturesare
encounteredtopreventmisfires.
Uselowsulfurcontentfuelhaving a pourpoint(ability
tofilter)ofatleast10°F (6°C)belowthelowest
expectedtemperature.Keepthefuelcleanand
protectedfromadverseweather.Leavesomeroom
forexpansionwhenfillingthefueltank.
Duetotheprecisetolerancesofdieselinjec-
tionsystems,itisextremelyimportantthefuel
bekeptclean.Dirtinthesystemcancauseseveredamagetoboth
theinjectionpumpandtheinjectionnozzles.
BLEEDING FUEL SYSTEM
Removethefuelreturnline,Figure6.Operatethe
primingleveronthefueltransferpumpuntilbubbles
ceasetoappearinthefuelflowingfromthebleed
hole. Replacefuelreturnline.
IMPORTANT:Ifthepumplobeonthecamshaftisup,crankthe
engineonerevolutiontopermithandpriming.Whenfinished,
retumthepriminglevertothedisengagedpositionfornormal
operation.
WORKTRANSFERPUMP
PRIMINGLEVERUNTIL
FUELFLOWSFROMRE-
TURNLINEFITTINGOF
INJECTIONPUMP.-
NOTE: IFPRIMINGLEVER
DOESNOTENGAGECRANK
ENGINEONEREVOLUTION.
FIGURE6.BLEEDINGFUELSYSTEM
GOVERNOR LINKAGE
Lubricatewithpowderedgraphite(preferably)ora
non-gumminglubricatingoil.Separatetheballand
socketbyshiftingthespring-loadedsleeveawayfrom
theendofthelink.Donotlubricatethetypewitha
plasticsocket.
INITIAL START
Checktheenginetomakesureithasbeenfilledwith
oiland fuel. Ifnecessarytoprimea dryfuelsystem,
returnthepriminglevertothedisengagedposition
10

afterpriming.Formoredetailedstartinginformation
seeStartingGuidepage51.
IMPORTANT:Thisunithasbeenrunandtestedforapproximately
4hoursatthefactory.Additionalbreak-intimeisrequiredandwill
varydependinguponloadconditions,oilused,etc.
Runasfollows:
1. Noload15-20minutes
2. Onethirdload30minutes
3.Twothirdsload2 to3 hours
Thenregularoperationcanberesumed.Avoidlight
loadoperationduringthefollowingseveralhoursfor
bestringseatingtocontroloil.
STARTING
1. Whenstartinga coldengineinambientsabove
55°F,pre-heatfor20seconds.
2. Continuetoholdpre-heatswitch:
a.PushthefuelsolenoidtoitsONposition.
b.PresstheSTARTswitch.
3.Releasestartswitchafterenginestartsand
reachesspeed.
4. Oilpressureshouldreadatleast20psi.Pressure
reliefvalveisnotadjustable.
Whenstartingattemperaturesbelow55°F,orunder
highhumidityconditions,refertosuggestedstarting
aidsinLowTemperaturesparagraphonthispage.
Whenrestartingengineaftershortperiodsofshut-
down, pre-heatisusuallynotnecessary.
STOPPING
Disconnectasmuchloadaspracticalfromtheengine
beforeshut-down.Pushthefuelsolenoidswitchtoits
OFFposition(thisde-energizesthesolenoid,closing
thethrottle).
Carbonintheexhaustsystemwilloccurin
dieselenginesoperatedconsistentlyatlight
loads. Operatetheengineatfullloadoccasionally(orforabout5
minutesjustbeforestopping)tocleanouttheexhaustsystem.
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.Plugexhaustoutlettokeepoutmoistureanddirt.
6.Cleanentireunit.Coatpartslikelytorustwith
lightgreaseoroil.
7.Providea suitablecoverfortheentireunit.
8.Disconnectbatteryandfollowstandardbattery
storageprocedures.
HIGH TEMPERATURES
1. Seethatnothingobstructsairflowtoandfromthe
engine.
2. Besuretheroomisproperlyventilated.
3.Keepthecoolingfinsclean.Seethatairhousings
areproperlyinstalledandundamaged.
LOW TEMPERATURES
1. UsecorrectSAENo.oilfortemperature con-
ditions.Changeoilonlywhenengineiswarm.If
anunexpectedtemperaturedropcausesan
emergency,moveenginetoa warmlocationor
applyexternallyheatedairuntiloilflowsfreely
(Donotuseanopenflame).
2. Preheatforoneminuteifthetemperatureis55°F
orlower.Ifenginefailstostartaftercrankingfor
oneminute,preheatforoneminutemoreandre-
attemptthestart.In extremecoldtemperatureit
maybenecessarytomaintainpreheatingupto2
minutesaftertheenginestartstoobtainfiringor
tosmoothoutallcylindersespeciallyatnoloador
lightloads.
CAUTION Donotusepreheatformorethanone
minutebeforecranking.Thiswillhelpto
preventheaterburnoutandconservebatterypower.
3.Protectfuelagainstcondensation.
4. Keepbatteriesina wellchargedcondition.
5.Reduceroomventilation,butusecaretoavoid
overheating.
DUST ANDDIRT
1. Keepengineclean.
2. Serviceaircleanerasoftenasnecessary.
3.Changecrankcaseoilevery100operatinghours.
4. Keepoilandfuelsuppliesindust-tight con-
tainers.
5. Keep governorlinkage connections clean.
HIGH ALTITUDE
Maximumenginepowerwillbereducedabout 4% for
each1000feetabovesealevel.
11

SERVICE AND MAINTENANCE
Beforeengine isputin operation,check all com-
ponents for mechanicalsecurity. Ifan abnormal
condition, defectivepart, or operatingdifficulty is
detected, repair or service as required.SeeFigure 7
forserviceandmaintenanceinstructions.Theengine
shouldbekeptfree of dust,dirt,andspilledoilorfuel.
Besureproperoperatingprocedure is followed.
ENGINE ROUTINE CHECK CHART
WHAT TO CHECK HOW TO 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
for properconnections.
Check for physicaldamage. Tightenconnections.
Replacedamagedconnectors.
Battery Checkelectrolytelevel. Keeplevelaboveplates.
Addonlydistilledwater as necessary.
MAINTENANCE SCHEDULE
Usethisfactoryrecommendedmaintenance(based
onfavorable operating, conditions)toserve 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 OPERATIONALHOURSMAINTENANCE ITEMS 8 50 100 200
|600 3000
InspectEngine X
CheckFuel x3
Check Oil Level X
Check Air Cleaner Xl
CleanGovernorLinkage
Xl'
ChangeCrankcase Oil x2
ReplacePrimaryFuelFilter Xl
ReplaceSecondaryFuelFilter Xl
CheckBatteryElectrolyteLevel X
Replace Oil Filter xi
EmptyFuelSedimentBowl X
xl - Moreoftenunderextremelydustyconditions.
x2 - See Operationsection for recommendedoils.
x3 - Water or foreignmateriai inthe fuel can ruin the injection
system. If dailyinspectionshowswater or excessive
dirt in primaryfilterbowl,-fuelhandling and storing
facilitiesshould be checked and situationcorrected.
Primaryfuelfiltermust be cleaned and secondaryfuel
filterreplacedfollowingcorrection of fuelcontamination
problem.
MAINTENANCE
ITEMS OPERATIONALHOURS
MAINTENANCE
ITEMS 200 500 1000 5000
CheckValveClearance •
.
x
CleanRocker BoxOil LineHoles x
InspectValves,Grind if Necessary X
Remove and Clean Oil Base X
CleanFuelSystem x
CleanEngine X
CompleteReconditioning X
CleanCrankcaseBreather X
CheckInjectionNozzles** X
CleanCrankcaseBreatherPipe
(BeginSpec V)
x
-Tightenheadbolts and adjustvalveclearanceafter
first 50 hours ona new'oroverhauledengine.
-Serviceonly by traineddieselequipmentpersonnel
withspecializedequipment.
For any abnormalities in operation,unusualnoises!loss of power,
overheating, etc., contactyourOnandealer.
12

CRANKCASEBREATHER .PR.OR TO SPEC S,
BREATHER TUBE
CAP
-BREATHER
TUBE BAFFLE
BEGINSPEC. V
CLEAN
CRANKCASE.
BREATHER
PIPE
TOBREATHER CAP
OPTIONAL AIR CLEANER
Keep oilatoil bathlevel.
Usesamegrade oilasin
crankcase.
KEEP OIL
ATTHIS
LEVEL
o o o o o e o o
OOOOOOO!
ooooooot
0 o 0 0 O 0 0 i
1
£)JLLEV£I5
EMPTYFUELSEDIMENT
BOWLEVERY 200 HOURS
SERVICINGSTANDARD AIR CLEANER
AFTER WASHING ELEMENT DIP
IN ENGINE OILAND SQUEEZE AS
DRY AS POSSIBLE.
FUELFILTERS
CONNECTOR
(Fromfuel
transferpump)
ELBOW
(Toinjection
pump)
PRIM ECONDARY
FILTER
DRAIN
Drainwaterperiodically as required.Replace
primaryfilterevery 600 hours.
Replacesecondaryfilterevery3000hours.
Performmoreoften in extremelydusty
conditions.
OILFILTERCHANGE
(SeeSchedule)
Place pan under old filter a:nd remove it
byturningcounterclockwise.Cleanfilter
mountingarea.Lubricategasket onnew filter
with oiland screwfilter on clockwiseuntil
gaskettouchesmountingbase,thentighten
turn.
FIGURE 7. MAINTENANCE PROCEDURES
13

COOLING SYSTEM
Toremovetheheatproducedduringoperation,these
enginesusea pressureaircoolingsystem.Bladeson
theengineflywheeldrawairintothefrontofthe
enginehousing,forcetheairpastallthecylindersand
outtherightsideoftheengine.SeeFigure8.
Fromtheengineoutlet,aircanbeductedoutofthe
area. Toimproveenginetemperaturecontrol,an
optionalshutterassemblycanbeinstalledontheair
outlet.SeeFigure9.
BLOWERHOUSING
BLOWERWHEEL
FIGURE8.COOLINGFLOW
MAINTENANCE
Witha properlyinstalledengine,maintenanceshould
consistofcleaningtheenginecoolingarea(finson
cylinderblockandcylinderheads)atregularinter-
vals, normallyevery1000hoursbutmoreoftenunder
dirtyoperatingconditions.
OVERHEATING
Thisissometimesdifficulttodiscoverinanair-cooled
engine.However,thefirstsignisusuallyengine
losingspeedmomentarilyorlowenginepower.This
happensbefbretheengineseizesandresultsin
scoredpistons.
AIRDUCT
AND
SHUTTER'
BLOWERHOUSING
FIGURE9.OPTIONALSHUTTERASSEMBLY
Themostprobablecausesofoverheatingaredirty
coolingsurfaces,operatingwithouttheengineair
housing, pooraircirculation,improperlubrication,
wronginjection'timingandengineoverloaded.
CAUTION Theairhousing,includingthedoor,mustbe
onwhenoperatingtheengine.Overheating
andpermanentdamagecouldresultfrom as little as oneminuteof
operationwithoutit..
Themostcommoninstallationproblemsleadingto
overheatingareasfollows:
1. Installationwithductsizetoosmallsoairflowis
insufficient.
2. Installationina smallroomwithnoductsand
insufficientairventilationintheroom.
3.Installationofairinletandoutletductssoair
outletfeedsbacktotheinlet.
AIRSHUTTER(Optional)
Whenused,theairshutterassemblyismountedatthe
engineairoutlet,ontherightsideofthecylinder
shroud. A thermostaticelement(Figure10)controls
14

theshutterssotheycloseandlimitairflowwhenthe
engineis cold. Whentheairtemperaturereaches
120°F,thepowerelementplungerbeginstomove
outward, openingtheshutters.Theshuttersare
completelyopenat140°F.
Theshutteropeningtemperatureisnotadjustable,
but,toassurecompleteopening,thepowerelement
plungermustcontacttheshutterrollpinatroom
temperature.Toadjustthis,loosenthepowerelement
mountingscrewsandslide,theassemblyuntilit
touchestherollpinwiththeshutterclosed.
Repair:Iftheshutterwillnotopen,checkthepower
elementfordefectsorbindingoftheplunger.Besure
theshutterdoesnotbindagainstthehousinginany
position.
Totestthepowerelement,removeitfromthe
assemblyandheatit.Whentheunitreachesabout
120°F,theplungershouldstarttomoveout.Total
movementshouldbeatleast7/32".Donotoverheat.
Iftheunitwillnotclose,checkfora weakreturn
spring, bindinginthenylonbearingsordirtinthe
powerelementplunger.Ifthenylonbearingsare
wornor bind, replace them. Removetheshuttersand
pulloutthestubshaft.Pushouttheoldandpushin
newbearingsfromtheinsideoftheshutterhousing.
Thelargebearingsurfaceserves asa spacebushing
soitmustbeontheinsideofthehousing.The
shuttersshouldbeadjustedtoobtainanendthrust
clearanceofnotmorethan 1/32".
HIGH TEMPERATURE CUT-OFF
Ahightemperaturecut-offswitchprotectstheengine
ifshutterfailstoopen.Theswitchisinserieswiththe
governorsolenoid.Switchisnormallyclosedand
opensatabout240°F.Whenitopens,thesolenoid
de-energizes,stoppingtheunit.Theswitchcloses
againatabout195°F.
SHUTTERS
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. SHUTTER CONTROLS
15

FUEL SYSTEM
Thedieselfuelsystemprovidesa meansoffiltering,
transportinganddeliveringfuelina finespraytothe
enginecylinderatthecorrecttimeforignition.The
systemconsistsofa primaryfuelfilter,fueltransfer
pump, secondaryfuelfilter,injectionpumpandan
injectionnozzle.Figure1-1showsthefuelsystem.
AIR
UCLEANER
J.
MANIFOLD
HEATER
NJECTION
NOZZLE
GLOWPLUG
CONNECTION
POINTFOR
FUELRETURN
LINE
INJECTION
PUMP
SECONDARY
FUELFILTER
INJECTION
NOZZLE
GLOWPLUG
FUELTRANSFER
PUMP
FUEL
SEDIMENT
BOWL
FUELFROM
LINEFILTER
PRIMARY
FUELFILTER
A9I8Re
FIGURE11.FUELSYSTEM
Thediaphragmfueltransferpumpwhichoperates
directlyofftheenginecamshaft,drawsfuelfroma
supplytankanddeliversitthroughtwofilterstothe
injectionpump.Theinjectionpumpmetersfueland
deliversitathighpressuretotheinjectionnozzleat
thecorrecttimeforignition.
Theinjectionnozzleopensata setpressure,deliver-
ingfuelina finespraytotheprecombustionchamber
forignition.
Excessfuelisreturnedtothetankaftereachinjection
cyclebya fuelreturnlinefromthenozzle.Anadapter
combinestheleak-offfuelwiththeflow-throughfuel
fromtheinjectionpump.A returnlineconnectedat
thispointreturnsthecombinedfuelbacktothefuel
supplytank.
Adieselenginecannottoleratedirtinthefuel
system. Itisoneofthemajorcausesofdiesel
enginefailure.A tinypieceofdirtintheinjectionsystemcanstop
yourunit.Whenopeninganypartofthefuelsystembeyondthe
secondaryfuelfilter,placeallpartsina panofcleandieselfuelas
theyareremoved.Beforeinstallingneworusedparts,flushthem
thoroughly,andinstallwhilestillwet.
MAINTENANCE
Inadditiontotheregularserviceperiods,changethe
secondaryfuelfiltercartridgewhenevertheengine
showssignsofstarvingfromlackof fuel. Removethe
secondaryfilterbyremovingthelargecapscrewin
thecenterofthefiltercover.Usecarewhenreplacing
thefiltercartridgetoavoidgettingdirtintothe
injectionpumppassages.
Whenreplacingorcleaningthefilters,bleedthefuel
system. Operatethehandprimingleveronthe
transferpumpuntilnoairbubblesflowfromthe
returnlinefittingoftheinjectionpump.Returnthe
priminglevertoitsoriginalposition.SeeFigure12.
WORKTRANSFERPUMPPRIMINGLEVER
UNTILFUELFLOWSFROMRETURNLINE
FITTINGOFINJECTIONPUMP•
FIGURE12.BLEEDINGFUELSYSTEM
CAUTION Ifthetransferpumpcamisonthehighside,
theprimingleverwillnotoperatethepump.
Tumtheengineonerevolutionbeforeoperatingtheprimelever.
StartingwithSpecS,a newfuelfiltrationsystem
accommodatesbothprimaryandsecondaryfuel
filtersona commonmountingcastingwhichisbolted
toa newly-designedoilfilltube.Theenginecannotbe
runwitheitherfilterlooseormissing,thusensuring
properfiltrationatalltimes.
Drainwaterperiodicallyasrequiredfrombothfilters
andsedimentbowl.Replaceprimaryfilterevery600
hoursandsecondaryfilterevery3000hours.When
replacingfilter,tightenscrewuntilgaskettouches
base, thentightenscrew1 to1-1/2turns.
16

FUEL TRANSFER PUMP
Thetransferpumpislocatedontheleftsideofthe
engineneartherear.Iffueldoesnotreachthe
secondaryfilter,makethefollowingchecksbefore
removingthepump.
1. Checkthefueltankandseethattheshutoffvalve
isopen.
2. Removethefuellinefromthetransferpump
outletandworktheprimingleveronthepump.
Fuelshouldspurtoutoffhepump.Ifnot,remove
thepumpforrepairorreplacement.
Testing: Ifthetransferpumpdelivers fuel, testitwitha
pressuregaugeormanometer.Performthesetests
beforeremovingthepumpfromtheengine.Remove
thepumpoutletandinstallthepressuregauge
(Figure13).
Testthevalvesanddiaphragmbyoperatingthe
primerleverafewtimesandwatchingthepressure.It
shouldnotdropoffrapidlyafterpriminghasstopped.
Next,runtheengineatgovernedspeedonfuel
providedbygravityfeedandmeasurethefuelpump
pressuredeveloped.Pressureshouldbebetween12
and14psiwiththegauge16"abovethefuelpump.
Alowpressurereadingindicatesextremewearinone
partorsomewearinallparts,andthepumpshouldbe
overhauledorreplaced.Ifthereadingisabove
maximum,thediaphragmisprobablytootightorthe
diaphragmspringtoostrong.Thiscanalsobecaused
byfuelseepingunderthediaphragmretainernutand
betweenthediaphragmlayers,causinga bulgeinthe
diaphragm.Overhaulthepumpandreplacethe
defectiveparts.
Lowpressurewithlittleornopressureleakafter
pumpingstopsindicatesa weakorbrokenspringor
wornlinkage,andinmostcases,thepumpshouldbe
replaced. Figure14showsthefueltransferpump.
UPPERPUMPBODY
LOWER
PUMPBODY ROCKERARMAND
LINKASSEMBLY
r;ROCKER
ARMPIN
FIGURE14.EXPLODEDVIEWOFJ-SERIESPUMP
Repair
Transferpumpfailureisusuallyduetoa leaking
diaphragm,valveorvalvegasket.A kitisavailablefor
replacementofvariousparts.Becausetheextentof
wearcannotbedetectedbythe.eye,replaceallparts
inthekit.Ifthediaphragmisbrokenorleaks,check
fordilutedcrankcaseoilandreplace.
Occasionally,failureisduetoabrokenorweakspring
orwearinthelinkage.In thiscase,replacetheworn
partsorinstalla newpump.Obtainreplacementparts
orinstallanewpump.Obtainreplacementpartsother
thantherepairkitfromanoriginalequipmentparts
distributor.
FUELPUMP
OUTLET
FIGURE13.FUELPRESSUREGAUGE
Fuel PumpRemoval Disassembly
1. Afterthepumpisremovedfromtheengine,scribe
alineontheflangesoftheupperandlowerpump
bodiestoassurecorrectpositioningwhen
reassembling.
2. Removethesecuringscrewsandseparatethe
upperandlowerpumpbodies(Figure14).
3.Torelease thepumpdiaphragm,pressdownori
thebaseofthediaphragmattheedgefarthest
fromthepumpmountingflange.Withoutreleas-
ingthisedge,pressdownontheoppositeedge.
Thisactionwillunhookthediaphragmactuating
rodfromtherockerarmlink(Figure15).
17

PRESSDOWNON.DIAPHRAGMBASE.HERE
DIAPHRAGM
ROCKERARM
STEPONE
CONTINUETOPRESSHERE
PRESSDOWNHERETOTIPDIAPHRAGM
ROD.OFFROCKERARMiLINK
DIAPHRAGM
ROCKERARM
STEPTWO
FIGURE15.REMOVALOFJ-SERIESDIAPHRAGMASSEMBLY
4. Withtheaidofa pliersorscrewdriver,pushand
tiptherockerarmreturnspringoffthecatchon
therockerarmandremovefrompump.
5.Cleanandinspectallpumpcomponentsnot
includedintherepairkit.Ifdamageisapparent,
replacethepump.
The- valveandcageassembliesontheJ seriespumpare
permanentlymountedIntheupperbodyofthepump.Ifthe.
.assembliesaredamagedornoticeablywom,theentirepump
mustbereplaced.
Assembly
4. Operatetherockerarmseveraltimestofullyflex
thenewdiaphragm.Whileholdingtherockerarm
fullyflexed,tightenthe securing, screws.
CAUTION Failuretofullyflextherockerarmwhile
tighteningthepumpbodiestogetherwill
resultinexcessivepumppressureand;possibleengine
floodingorpumpdiaphragmfailure..
NOZZLE
Theinjectionnozzleistheconventionalinward:
openingpintletypewithadjustableopeningpressure.
Itisfactoryadjustedto.openat 1900 to 1950 psi. After
severalhundredhoursofoperationthenozzle
pressurewilldecreasetoapproximately1750 psi. Do
notdisassemblethenozzleoradjustnozzlepressure
withoutpropertestequipment.A nozzlepressure'
testerisessentialtodothiswork.
inspection
Toinspectthenozzlespraypattern,removethe
nozzlefromthecylinderhead.Cranktheengine,let
thenozzlesprayintotheairandwatchthepattern;
Thesprayshouldbeconeshapedwitha solid-
appearingcentersurroundedbycloudlikefogin
whichthesprayis.evenly atomized. See Figure 16. An
apparentchatteringofthenozzleisnormal.
Ifstreamersare visible,, thepatternisbadlydistorted
orthenozzledripsbeforeitreachesopening
pressure,itisdefective,andmustbecleanedor
replaced.
CAUTION
seriousinfection..
Donotletthe nozzle: sprayagainstyourskim
Thefuelcanpenetratefleshandcausea
1. Lubricatethediaphragmactuatingrodandinstall
thenewdiaphragminthepump.Reversethe
procedureusedforremoval,rollingbackthe
diaphragmfabrictoviewtherockerarmlink
(Figure 15). Holdthepumpbodyupside-downso
thatthe.weightofthelinkwillkeepitwithinreach
ofthediaphragmactuatingrod.
2. Installthenewrockerarmreturnspring.
3.Placetheupperandlowerbodiesofthepump
togetherwiththescribemarksaligned.Startthe
sixsecuringscrews,makingsuretheydonot
chewintothediaphragmfabric. Leave the screws
2or3 turnsloose.
GOOD
SPRAY
PATTERN ^.
POOR
SPRAY
PATTERN
FIGURE16.NOZZLESPRAYPATTERN
18