Onan RDJE User manual

Service
Diesel Engines
974-0250
(SPEC A)
10-88
Printed in U.S.A

Safety Precautions
Itisrecommended that you readyour engine manual and
become thoroughly acquainted with your equipment be-
fore you start the engine.
WARNING
Thissymbolls used throughoutthis
a manual to warn of possible serlous
personalinjury.
Thlssymbol refers
to possibleequip-
ment damage.
Fuels, electrical equipment, batteries, exhaust gasesand
movingparts presentpotential hazardsthatcouldresult in
serious, personal injury. Take care in following these
recommended procedures.
Safety Codes
0 All local, state and federal codes should be consulted
and complied with.
0 This engine is not designed or intended for use in
aircraft. Any such useisat the owner's sole risk.
General
0 Provideappropriate fire extinguishers and install them
.
inconvenientlocations.Useanextinguisher ratedABC
by NFPA.
0 Make sure that all fasteners on the engine are secure
and accurately torqued. Keep guards inposition over
fans, driving belts,etc.
Ifitisnecessarytomakeadjustmentswhiletheengine is
running, use extreme caution when close to hot ex-
hausts, moving parts,etc.
.
ProtectAgainst Moving Parts
0 Do not wear loose clothing in the vicinity of moving
parts, such as PTO shafts, flywheels, blowers, coup-
lings, fans, belts, etc.
0 Keepyour handsaway from moving parts.
Batteries
0 Beforestarting work ontheengine, disconnect batter-
ies
to preventinadvertent starting of the engine.
0 DO NOT SMOKE while servicing batteries, Leadacid
batteriesgiveoffahighlyexplosive hydrogengaswhich
canbeignitedbyflame, electricalarcingorbysmoking.
0 Verifybattery polaritybeforeconnecting battery cables.
Connectnegative cable last.
Fuel System
0 DO NOT fill fuel tanks whileengine isrunning.
DO NOTsmoke or usean openflame inthe vicinity of
the engine or fuel tank. Internal combustion engine
fuels are highlyflammable.
Fuellines must beof steel piping,adequately secured,
and free from leaks. Piping at the engine should be
approved flexible line. Do not use copper piping for
flexible lines as copper will work harden and become
brittleenoughtobreak.
Be sureall fuel supplies havea positiveshutoff valve.
.I
Exhaust System
Exhaust products of any internal combustion engine
are toxic andcancause injury, or death if inhaled.
All
engine applications, especially thosewithinaconfined
area, should be equipped with an exhaust system to
discharge gases tothe outside atmosphere.
Do notuseexhaustgasestoheatacompartment.
0 Make sure that your exhaust system is free of leaks.
Ensurethat exhaust manifolds are secure and are not
warped bybolts unevenlytorqued.
Exhaust Gas is Deadly!
Exhaustgases containcarbonmonoxide,apoisonousgas
that might cause unconsciousness and death. It is an
odorless and colorless gas formed during combustion of
hydrocarbon fuels. Symptoms of carbon monoxide poi-
soning are:
0 Dizziness Vomiting
0 Headache MuscularTwitching
WeaknessandSleepiness
If youexperienceanyofthesesymptoms, getoutintofresh
air immediately, shutdownthe unitanddo not use untilit
has beeninspected.
The bestprotectionagainst carbon monoxideinhalationis
proper installation andregular,frequent inspections
of the
complete exhaust system. If you notice a change inthe
soundorappearance ofexhaustsystem,shuttheunitdown
immediatelyand have
it inspectedandrepairedatoncebya
competent mechanic.
'CoolingSystem
0 Coolants under pressure have a higher boiling point
thanwater. DONOTopenaradiatorpressurecapwhen
coolant temperature
is above 212°F (lOO°C) or while
engine isrunning.
Throbbing inTemples
Keep the Unit and Surrounding Area Clean
Make sure that oily rags are not left on or near the
engine.
Removeall unnecessary grease and oilfrom the unit.
Accumulatedgreaseand
oil cancauseoverheating and
subsequentenginedamageandpresentapotentialfire
hazard.
E-4

*
TABLE OF CONTENTS
PART I SERVICE MANUAL
Specifications
..................................................... 2
Dimensionsand Clearances ........................................ 3
Assembly Torques and SpecialTools
................................ 5
Engine Troubleshooting
............................................ 6
Service and Maintenance
.................................. ; ........ 7
Exhaust System .................................................. 11
Cooling System ................................................... 13
Fuel System ...................................................... 16
Governor System
................................................. 33
Starting System
.................................................. 35
Engine Disassembly
.............................................. 42
Control System ................................................... 54
Oilsystem ....................................................... 30
TO AVOID POSSIBLE PERSONAL INJURY OR
VICE REPRESENTATIVE MUST PERFORM ALL
S E R VICE .
EQUIPMENT DAMAGE. AN AUTHORIZED SER-
1

SPEClFl CATIONS
RDJEIRDJEA
Dimensions(inches)
Height
........................................................................... 28.71 (729.2 mm)
Width ............................................................................ 19.75 (501.6 mm)
Length..
......................................................................... 23.04 (585.2 mm)
............................................................................. 307 Ib.
Weight
2
Number of Cylinders (in-line) .......................................................
Displacement (cu in.) ............................................................. 70 inch3 (1.2 litre)
Bore
3.5 (88.96 mm)
Stroke
3.625 (92.08 mm)
yes
Oil Control..
.................................................................................... 1
Stellite Faced Valves.. ........................................................................... yes
Stellite ReplaceableValve Seats
.................................................................. Yes
Valve Rotator..
................................................................................... Yes
Governor (internal flyball type-externally adjustable)
............................................. Yes
Governor Regulation (percent)
..................................................................... 5
Nominal BatteryVoltage ........................................................................... 12
SAE Group lH, 6 volt.. ........................................................................ two
Amp/Hr SAE
20 hr (minimum). ........................................................ 120 (432 kC)
. Solenoid Shift Starter. yes
Injection Pump (American Bosch type)
.......................................................... PSU
.............................................................................. 1-2
Primary and Secondary Fuel Filters.. ............................................................. Yes
Fuel Pump Lift (feet)..
.................................................................... 6 (1.8 m)
Oil Pump (gear type) ............................................................................ yes
Oil Filter (full flow) ............................................................................... yes
Oil Capacity
U.S. quarts (includes Filter). ................................................ 3 (2.84 litre)
Exhaust Connections (pipetapped).
.................................................. 1-1/2(38.1 mm)
Shaft Length
......................................................................... 4 (101.6 mm)
Keyway Length..
...................................................................... 3 (76.2 mm)
Keyway Width..
..................................................................... 3/8(9.53 mm)
Keyway Depth..
.................................................................... 3/16 (4.76 mm)
Compression Ratio
....................................................................... i .... 19.O:l.O
.................................................................................
.............................................................................
Main Bearings are Leaded Bronze, PrecisionType for Replacement (qty.) ............................ 2-
Compression.. .................................................................................. 3
Connecting Rod BearingsTri-metal Replaceable ..................................................
PistonRings (chrome plated)
BatterySize
...........................................................................
Injection Order
Power Take-off (inches)
Shaft Diameter
.................................................................... 1-314.(44.5 mm)
NOTE: The RDJE and RDJEA are almost identical engines, the differences being that the RDJEisan even firing engine; both
pistonsmoveupanddowntogether. TheRDJEAisanoddfiringengine;onepistonmovesupwhiletheother movesdown.
For the
above reasons,the crankshafts, injection pumps, camshafts,and associated piece parts are different.
2

DIMENSIONS AND CLEARANCES
RDJWRDJEA
All clearances given at room temperature of 70°F (21°C) .
All dimensions in inches (millimetres in parentheses) unless otherwise specified.
d .
CAMSHAFT
Bearing Journal Diameter. Front ....................................... 2.500-2.505 (63.500-63.627)
Bearing Journal Diameter. Rear
..................................
1.1875-1.1880 (30.1625-30.1752)
Bearing Clearance Limit
........................................... 0.0015-0.0030 (0.0381-0.0762)
End Play
............................................................. 0.007-0.039 (0.1778-0.9906)
Cam Tappet Diameter
............................................. 0.875-0.873 (22.1615-22.1742)
Cam Tappet Hole Diameter
......................................
0.8755-0.8765 (22.2377-22.2631)
Large Bore Diameter
............................................. 2.1871-2.1876 (55.5523-55.5650)
Small Bore Diameter
................................................. 1.044-1.045 (26.5176-26.543)
(Center-to-Center)
............................................. 5.998-6.002 (152.3492-152.4508)
Clearance, Bearing to Crankshaft
...................................... 0.001-0.003 (0.0254-0.0762)
Bore HonedDiameter
.............................................. 3.4995-3.5005 (88.8873-88.91 27)
MaximumAllowable Taper
.............................................................. 0.005 (0.127)
MaximumAllowable Out-Of-Round
...................................................... 0.001 (0.025)
Main Bearing Journal Diameter
..................................... 2.2437-2.4450 (56.989-62.103)
Main Bearing Clearance
............................................. 0.0030-0.0043 (0.076-0.109)
Connecting Rod Journal Diameter
................................
2.0597-2.0605 (52.3240-52.3367)-
Rod Bearing Clearance ............................................ 0.0019-0.0038 (0.0482-0.0965)
End Play
............................................................... 0.010-0.015 (0.254-0.381)
CONNECTING RODS
Large Bearing Boreto Small Bearing Bore
CYLINDER
CRANKSHAFT
PISTONS AND RINGS
Clearance in Cylinder
Measure 90" to pin. just below oil ring
............................... 0.0055-0.0075 (0.1397-0.1905)
Ring Groove Width
TOP
.......................................................... 0.0970-0.0980 (2.464-2.489)
NO 2 ......................................................... 0.0965-0.0975 (2.451-2.477)
NO 3 ......................................................... 0.0965-0.0975 (2.451-2.477)
NO 4 ......................................................... 0.1880-0.1897 (4.775-4.81 8)
Width-All Rings
.................................................. 0.0925-0.0935 (2.3495-2.3749)
Clearance
in Piston ................................................................ Thumb Push Fit
Connecting Rod Bushing Clearance
................................ 0.0002-0.0007 (0.0050-0.0178)
..............................................................
RingGap 0.010-0.020 (0.254-0.508)
PISTON PIN
STARTING
MOTOR (Prestolite)
........................................................................
Rotation Counterclockwise
Pinion Clearance to Pinion Stop (Solenoid Plunger Bottomed)
..............
0.070-0.120 (1.78-3.05)
Pinion Rest Position-Distance from Pinion Housing
Mounting Face to Outer Edge
of Pinion ...........................
1-9/32 - 1-15/64 (32.54-37.31)
Armature End Play
...................................................... 0.005-0.030 (0.030-0.760)
Stem Diameter
....................................................
0.3405-0.3415 (8.6487-8.6741)
Guide Clearance
.................................................. 0.0015-0.0030 (0.0381-0.0762)
Valve Face
........................................................ : ............................ 42"
VALVE-INTAKE
...........................................................................
Clearance 0.017 (0.4318)
3

VALVE-EXHAUST
Stem Diameter
.................................................... 0.3405-0.3415 (8.6487-8.6741)
Guide Clearance .................................................. 0.0025-0.0045 (0.0635-0.1143)
Valve Face .................................................................................... 45'
Clearance ........................................................................... 0.017 (0.4318)
Length ............................................................................ 1.7812 (45.2424)
Outside Diameter ................................................. 0.469-0.4696 (11.9126-11.9253)
Exhaust ...................................................... 0,344-0.345 (8.7376-8.7630)
Intake........................................................ 0.342-0.343 (8.6868-8.7122)
Cylinder Block Bore Diameter ...................................... 0.467-0.468 (11.8618-11.8872)
Bore Diameter
intake
........................................................ 1.361-1.362 (34.570-34.595)
Exhaust ....................................................... 1.364-1.365 (34.646-34.671)
Depth (from cylinder head face) .................................... 0.433-0.439 (10.9982-1 1.1506)
I nsert-Outside Diameter .......................................... 1.364-1.365 (34.6456-34.671 0)
Seat Width ........................................................ 0.0469-0.0625 (1.1912-1.5875)
Angle ......................................................................................... 45'
Available Oversizes .................................................................. 0.002 (0.0508)
VALVE GUIDE
Inside Diameter (after reaming)
VALVE SEATS
0.005 (0.127)
0.010 (0.254)
0.025
(0.635)
VALVE SPRINGS . *
Load-Valve Open ....................................................... -87-97 Ibs (12.0-13.4 N*)
Load-Valve Closed ....................................................... 45-49 ibs (6.2-6.8 N')
N . Base unit . Newtons . Unit of force .
4

ASSEMBLY TORQUES AND SPECIAL TOOLS
The assembly torques given herewill assure proper
tightness without danger of stripping threads. If a
torque wrench
is notavailable, estimatethedegreeof
tightness necessary for the stud, nut, or screw. Be
careful notto stripthreads. Usereasonableforceonly
and a wrench of normal length.
Specially designed place bolts do not require a
lockwasher or gasket.
Do not attempt to use a
lockwasher with these bolts;
it will defeat their
purpose. Check all studs, nutsandscrewsoften,and
tighten as neededto keep them from working loose.
SPECIAL TOOLS
These toolsare availablefrom Onanto aid serviceand
repair work.
Crankshaft gear pullingring.
............. .420-0275
Diesel nozzle tester ..................... .420-0184
Diesel pintlenozzle cleaning tool set
(includes injection nozzle centering
tool)
.................................. 420-0208
Driver,Valve seat ....................... .420-0270
Oil seal guide and driver.. ............... .420-0456
Nozzle centering sleeve ................. .420-0321
Diesel nozzletester ..................... .420-0322
Combination main and cam
bearing driver
........................ .420-0326
Dieselcompression tester ............... .420-0283
Valve spring compressor tool ............ .420-0210
Valve seat remover.. .................... .420-0311
Flywheel puller ......................... .420-0100
TORQUE SPECIFICATIONS F1.-Lb. Nom
Connecting rod bolt
............ 27-29 (37-39)
Rocker-Box cover ..............
8-10 (1 1-14)
Cylinder head bolt. ............. 44-46 (60-62)
Exhaust manifold nuts .......... 13-15* (18-20)
Flywheel mounting screw ....... 65-70 (88-95)
Fuel pump mounting screws .... 15-20 (20-27)
Gear case cover ................ 15-20 (20-27)
Injection nozzle mounting
Injection pump mounting
screws
....................... 15-16 (20-22)
Intake manifold.. ............... 13-15 (1 8-20)
Oil base mounting screws.. ..... 45-50 (61-68)
Oil Filter ..........
Hand tight plus 1/4 to 1/2 turn
Oil pump mounting screws..
.... 15-20 (20-27)
Rear bearing plate. ............. 40-45 (54-61)
Glow plug.. .................... 10-15 (18-20)
screws ....................... 20-21 (27-28)
Rocker arm nut.. ............... 4-lo** (5-13)
Rockerarm stud.. .............. 55-60 (75-81)
- Exhaust nuts must be tightened evenly.
** - This torque is due to friction between the threads
only and locksthe nuts in place. Usethe rocker
arm nut to adjust valve lash.
5

ENGINE TROUBLESHOOTING
6

SERVICE AND MAINTENANCE
PR E-STARTI N G
Preparationsfor the initial and each additional star-
ting operation should include careful checks of the
oil, fuel, cooling,and electricalsystems. Thecylinder
air housingdoorshould beclosed withallairshrouds
in place.
Before engine is put in operation, check all com-
ponents for mechanical security. If an abnormal
condition, defective part, or operating difficulty is
detected, repair or service as required. The engine
should bekeptfreeof dust,
dirt, andspilledoil orfuel.
Be sure proper operating procedure is followed.
Crankcase Oil: Use an oil with the API designation
CD/SD or CD/SE. However, to reduce oil consump-
tiontoanormallevelintheshortesttimepossibleona
new or rebuilt engine, use CCoil for thefirst fill only
(50 hours). Then use the recommended oil only.
Select the correct SAE grade oil by referring to the
following:
Above
32" F (0" C) ....................... SAE 30
0" F to 32" F (-18" C to 0°C) ... SAE 1OW or 5W-30
Below 0" F (-18" C) .................. SAE 5W-30
Multigradeoilsare recommendedfortemperatures of
32" F (0" C) and below, buttheyarenotrecommend-
edfortemperatures above
32" F (0" C).Whenadding
oil between oil changes,
it is preferable to use the
same brand as various brands of oil may not be
compatible when mixed together.
Never remove 011 level Indicatorcap with the
engine running, because oil will blow out of
the tube causingpossibleinjury.
RecommendedFuel: Although number 2 diesel fuel
gives the best economy for most operating con-
ditions, number
1 diesel fuel can be used:
1. When ambient temperatures are below 32°F
2.
During long periods of light engine load; or,
3. If preferred by user.
(0" C);
Uselowsulfurcontentfuel havingapourpoint(ability
to filter) of at least 10" below the lowest expected
temperature. Keepthe fuel clean and protectedfrom
adverse weather. Leave some room for expansion
when filling the fuel tank.
Dueto the precisetolerances of dieselinjec-
tion systems,itisextremelyimportantthefuel
be keptclean. Dirt in the systemcancauseseveredamageto both
the injectionpump and the injectionnozzles.
Bleed air from fuel system as follows: Disconnectthe
fuel return line. See Figure 1
. Operate the hand
priming lever on diaphragm type fuel transfer pump
untilthere are no air bubbles in fuel flowing fromthe
fuel return line fitting. Then connect the fuel return
line.
'WORK TRANSFER PUMP
PRIMING LEVER UNTIL
FUEL FLOWS FROM
RETURN
LINE FITTING
OF INlECTlON PUMP.
FIGURE 1. BLEED FUEL SYSTEM
If the camshaft pump lobe is up, crank engineone revolution to
permit hand priming. When finished, returnpriminglever inward
(disengaged position) to permit normal pump operation.
7

PRE-HEATING AND STARTING
Extremes in starting temperatures may require ad-
ditionalpreheating. Ifenginefailstostartquickly, rest
engineseveralseconds and repeatstartingsequence.
CAUTION
If enginedoes notstartonfirstattempt,check
fuel system. Limit pre-heating to one minute
periods: longer periodscan ruin the heater elements.
.1.
2.
3.
4.
For cold engine starting below
55" F (13" C),
depress manifold heater switch for one minute
only.
PushSTART-STOPswitchtoitsSTARTposition.
Releaseswitches after engine starts and reaches
speed.
Oil pressure should read at least20 psi (pressure
relief valve is not adjustable).
On"standard" model, depress preheat switchfor one minute and
thenpushstartswitch. Bothswitchesmustbeengagedforstarting.
Do not apply overvoltage to the starting
circuit at any time. Overvoltagewill destroy
the glow plugs and air heater in
2 to 3 seconds. If it becomes
necessary to use an additionalsource of power to startthe set
-
use a 12 volt battery connected in parallel.
AUTOMATIC STARTING AND STOPPING
Optionalcontrolsmaybeusedfor automaticstartand
stop, but must provide engine preheating.
The automatic control should haveatimedelay relay
to preheat glow plugs and the manifold heater for
about 20 seconds before cranking occurs. The time
delay relay prevents immediate engagement of the
starter incasethe load is reappliedbeforetheengine
stops.
STOPPING
1. Push fuel solenoid switch to stop position.
2. Releaseswitch when set stops. Ifstop circuitfails,
close fuel valve.
APPLYING LOAD
If practicable, allow engine to warm up before
connecting a heavy load. Continuous overloading
causes highoperatingtemperatures thatcandamage
the engine. The exhaust system may form carbon
deposits during operation at light loads; apply full
load occasionally before shut-down to prevent ex-
cessive carbon accumulations.
Try to connecttheloadinsteps insteadof full loadat
one time.
EXERCISE
Infrequent use results in hard starting. Operate at
least
30 minutes each week. Run longer if battery
needs charging.
BREAK-IN PROCEDURE
The unit should be run inthe following sequence:
1. One half hour at 1/2 load.
2. One half hour at 3/4 load.
3. Full load.
Continuous running under one half load during the
first few hundred hoursusually resultsinpoorpiston
ring seating, causing higher than normal oil con-
sumption and blowby.
Drainandreplacethecrankcaseoilafterfirat 50 hounofoperation;
drain while the englne Is stlll hot.
INSPECTION
Check for alignment of engine and load. Misalign-
ment will cause excessivevibrationandbearingwear.
Make a visual inspection of the entire installation.
VENTILATION
Good ventilation is needed to cool theengine andto
support combustion. Avoid recirculation of ven-
tilating air. See
SPEClFlCATlONS for air flow re-
quirements and vent sizes.
Utilizing exhaust heat to warm a room or
compartment occupied by people is not
recommendeddue to possible leakage of exhaustgases.
EXHAUST GASES ARE DEADLY
71 POISONOUS!
EXHAUST
Pipeexhaust gas outsideany enclosure - exhaust gas
is poisonous. Exhaust pipes must notterminatenear
inlet vents. Avoid sharp bends. Use sweeping, large-
radius elbows. Use a section of seamless, flexible
tubing between the engine and any rigid pipe to
restrict vibration. Increase exhaust pipe one sizefor
each additional
10 feet (304.8 cm) in length.
BATTERIES
Check the condition of the starting batteries at least
every two weeks. See that connectionsareclean and
tight. A light coating of non-conductive grease will
retard corrosion at terminals. Keep the electrolyteat
the proper level above the plates by adding distilled
water. Checkspecific gravity; rechargeifbelow1.280.
DUST AND DIRT
1. Keep radiator free of dirt, etc.
2. Service air cleaner as frequently as necessary.
3. Change crankcase oil every
50 operating hours.
4. Keep
oil and fuel in dust-tight containers.
5. Keep governor linkage clean.
HIGHALTITUDE
Maximum power will be reduced approximately 4
percent for each 1000 feet (310 m) above sea level,
after the first
1000 feet (310 m).
8

LOW TEMPERATURES
1. Use correct SAE No. oil for temperature con-
ditions. Changeoil onlywhen engine iswarm. If
an unexpected temperature drop causes an
emergency, move engine to a warm location or
apply heatedair (neveruseopenflame) external-
ly until oil flows freely.
2. Use fresh fuel. Protect against moistureconden-
sation.
3. Keep fuel system clean, and batteries
in a well
charged condition.
4. Partically restrict cool air flow but use care to
avoid overheating.
5. Useadditional preheat cyclesduring cold starts.
.Do not exceed one minute preheat
!cz3 periods; longer periods can ruin the
heater elements.
CAU~l~~
in dusty
conditions)
100
200
500
600
OUT-OF-SERVICE PROTECTION
The natural lubricating qualities of No. 2 diesel fuel
should protect a diesel engine for at least 30-days
when unit is not
in service. To protectanenginethat
will beout of service for morethan 30 days, proceed
as follows:
1. Runengine untilthoroughly warm; underat least
50 percent load.
2. Shut down engine and drain oil base while still
warm. Refill and attach a warning tag indicating
viscosity of
oil used.
3. Remove glow plugs. Pour 1-ounce of rust
in-
hibitor (or SAE#10 oil) intoeach cylinder. Install
Crank engine byhand only to distribute
m oil in cylinder. Starter cranking is too
fast: oil or inhibitor fluid will fire if cranked with starter at
normal roomtemperature.
glow plugs.
CAUTION
Check air cleaner.
Clean governor linkage,
Change crankcase oil
Drain fuel condensation traps
in lines and filters,
see Note
1
Clean crankcase breather
Replace oil filter
Check battery condition
Check.start-disconnect circuit
Check valve clearances
Change primary filter
4. Service air cleaner per Maintenance Schedule.
5. Clean throttle and governor linkage and protect
6. Plug exhaust outlets to prevent entrance of
7. Clean andwipeentireunit.Coatpartssusceptible
8. Disconnect battery and follow standard battery
by wrapping with a clean cloth.
moisture, bugs, dirt, etc.
to rust with a light coat of grease or oil.
storage procedure.
3000
I 5000
Returning a Unit to Service.
1. Remove cover and all protective wrapping.
Remove plug from exhaust outlet.
2. Check warning tag on oil baseandvertify that oil
viscosity is still correct for existing ambient
temperature.
3. Cleanandcheckbattery.Measurespecificgravity
(1.260 at 77" F [25" C]) and verify level is at split
ring. Ifspecific gravity islow,charge untilcorrect
value isobtained. Iflevelislow,adddistilledwater
and charge until specific gravity is correct. DO
NOT OVERCHARGE.
Change secondary fuel filter
General overhaul (if required)
see Note
3
Donotsmoke whileservicing batteries.
Explosive gases are emitted from
batteries
in opeation. Ignition of thesegasescancausesevere
personal injury.
4. Check thatfuelinjectorsandfuel linesaresecure,
correctly torqued.
5. Clean radiator.
6. Connect batteries.
7. Verify that no loads are connected to engine.
8. Start engine.
After engine has started, excessive blue smoke will be
exhausted untilthe rust inhibitor oroilhas burnedaway.
Before commencing any maintenance work
onthe engine, controls, orassociated equlp-
ment, disconnect batteries.Failuretodo
so couldresult in damage,
serious personal injury
In the event of inadvertent starting.
OPERATOR AND SERVICE MAINTENANCE SCHEDULE
I HOURSOF I I
I I
OPERATION MAINTENANCE TASK
I
Inspect exhaust system
Inspect engine
Check fuel SUPDIV, see Note 1
I Check oil leve1:See Figure 2.
50 (more often I
I
2000
Grind valves (if required)
Clean holes in rocker box
oil line and orifices
Check nozzle spray pattern,
see Note
2
NOTE 1. Water or foreign material in fuel can ruin the injection
system. Ifdaily inspection shows waterorexcessivedirt
in sediment bowl fuel, handling and storing facilities
should bechecked and situation corrected. Primary and
secondary fuel filters must bereplacedfollowingcorrec-
tion of fuel contamination problem.
2. This service must be conducted by trained diesel
injection equipment personnel with suitable test
facilities. Omitthis service
until theseconditionscanbe
met.
3. Tighten head bolts and adjust valve clearance afterfirst
50 hours on an overhauled engine.
9

OIL DRAIN EXTENSION
For service convenience, install ashort (lessthan 10
inches [254 mm]) oil drain extension made from
standard pipeand fittings inthe1/2-inch (12.70
mm)
pipe-tapped oil drain hole in the base.
FUEL FILTER
FllEL PUMP
BALLJOINT
BREATHER
\% HOSE
CAP AND VALVE
BREATHER TUBE
RDJE BREATHERTUBE
AMP'
OIL FILTER CHANGE
Place pan under old filter and remove by turning
counterclockwise. Clean filter mounting area.
Lubricategasketonnewfilter with oil andscrewfilter
on clockwise until gasket touches mounting base,
then tighten
1/2 turn.
Never remove 011 levelIndicatorcap with the
engine running, becauseoil will blow out
of
the tube causing possible Injury.
OIL LEVEL INDICATOR
INLET OUTLET
ONDARY
FILTER FILTER
DUAL FUEL FILTER SYSTEM
TO BREATHERJTUBE
L.2.
RDJEA BREATHER PiPE
FIGURE
2. MAINTENANCE PROCEDURES
10

GENERAL
The exhaustsystem mustefficiently expel all engine
combustion productsand muffleexhaustnoiseswith
minimumback pressure. Ifbackpressure istoo high,
the volumetric efficiency of the engine is reduced,
fuel economydrops, exhausttemperatureincreases,
end valve life is shortened.
Back pressure must not exceed
27 inches (686 mm)
of water column for the rated load when measured
withamanometerat
the exhaustmanifold, Figure 3.
FIGURE 3.
BACK PRESSURETEST WITH MANOMETER
Exhaust Smoke
A light gray or light blue smoke is a result of low
ambient temperature and light load. This smoke is
unburned fuel (not harmful to the engine) and
disappears when more load is applied.
Black smoke indicates overfueling (more fuel than
oxygen) and is usually caused by overloading.The
smokeorunburnedfuel becomescarbonwhen raised
to a hightemperature. Carboncontributes toengine
damage because it sticks to rings and fuel injection
nozzles.
EXHAUST GASES ARE DEADLY
-1 POISONOUS!
Vent exhaustgases outside. Useflexibletubing only
between the engine exhaust outlet and rigid piping.
WARN~NG
On service calls, always inspect exhaust
= systems for possible leaks. Report any ex-
hausthazardstotheowner/operatorandwarnthem
of thepotential
dangers to life
if not repaired.
INSTALLATION TIPS
Points to remember when installing an exhaust
system are:
Exhaust pipesshould beas shortaspossiblewith
a minimum of fittings.
The muffler must be as close to the engine as
possible. Mufflers which are too far from the
manifold remaincool and collect carbon residue.
Pitch exhaust pipe upward from exhaust outlets
toavoidentrapmentof rawdieselfumesinmuffler
at shutdown.
Avoid sharp bends by using large radiuselbow.
Check back pressure with a mercury or water
column type manometer.
Position the exhaustoutletaway fromtheengine
air intake.
Exhaust noisecan be suppressedor reduced by:
Usinga heavy duty exhaust system with a more
efficient muffler.
Avoiding use of flexible lines.
Installing a deflector at the exhaust outlet to
direct exhausttoward the ground, butaway from
the operator.
Using a resonator in addition to a muffler.
The importance of exhaust systems (normally
supplied by the customer) cannot be over-
emphasized. A poor or clogged system causes low
power, overheating and engine damage.
A poor
exhaust system increases back pressure which
reducesefficiency.
If the manufacturer tailon his own exhaust
system, an Onan applicationsengineermust
approve the installationfor warranty purposes.
11

SINGLE THIMBLE DIAMETER
12” (30s mm) LARGER OR
DOUBLE VENTILATED THIMBLE
DIAMETER
6” ( 152 mm) LARGER
INDOOR INSTALLATIONS
Locate exhaust outlet far from air inlet to avoid
recirculation. The engineexhaustistappedfor
1-1/2
inchthread. Useflexible tubingtoconnecttheengine
exhaust to rigid pipe or muffler. Shield the line
if it
passesthrough acombustiblewall (Figure
4). Ifturns
are necessary, usesweeping (large radius)elbows. If
pitchedupward, installacondensationtrapat pointof
rise, Figure
5.
THANEXHAUS? LINE
S IN END
SLEEVE
EXHAUST LINE PASSING THROUGH
II WALL OR PARTITION
FIGURE 4. EXHAUST SHIELD
IF EXHAUST LINE MUST BE PITCHED
UPWARD CONSTRUCT A TRAP OF PIPE
,. FITTINGSAT POINT OF RISE
DRAIN CONDENSATIONTRAP
PERIODICALLY
A617
FIGURE 5. CONDENSATIONTRAP
\WARNING)
ENGINE EXHAUST GAS (CARBON MONOXIDE) ISDEADLY!
Carbon monoxide is an odorless, colorless gas formed by incomplete
combustion of hydrocarbon fuels. Carbonmonoxide is a dangerousgas that
cancause unconsciousnessandispotentially lethal. Someof thesymptomsor
signs of carbon monoxide inhalation are:
Dizziness Vomiting
IntenseHeadache
Weakness and Sleepiness
.. MuscularTwitching
Throbbing in Temples
If you experience any of the above symptoms, get out into fresh air
immediately.
Thebestprotectionagainstcarbonmonoxideinhalationisaregularinspection
of the complete exhaust system.
If you notice a change in the sound or
appearance of exhaust system, shut the unit down immediatelyand have it
inspectedand repairedat once by a competent mechanic.
12

COOLING SYSTEM
RADIATOR COOLED SYSTEM
On radiator cooledmodels(Figure6), thewaterpump
draws cooled water from the radiator through the
bottom hose and forces it into the cylinder water
jacket at thefront of the engine. The water circulates
through the cylinder water jacket up through the
eylinder headsintothethermostat andflowsthrough
theoutlethoseintothetopof theradiator.Itcirculates
downthroughtheradiatorwhilethefan blowscooling
air across the radiator. The water is drawn from the
bottomof the radiator by thepumpto berecirculated.
WATER PUMP
-- WATER FLOW, ENGINE COOLING
c/"L AIR FLOW, ENGINE VENTILATION
LEGEND
FIGURE 6. RADIATOR COOLING SYSTEM
During engine warmup, when the thermostat is
closed, the water bypasses the radiator.
It flows
throughabypasslinefromthewateroutlethousingto
the pump and recirculates through the engine, until
PUGLEY
HOUSING GASKET
FIGURE7a. WATER PUMP-EXPLODED VIEW
the water reaches normal operating temperature.
Recirculation ensures both rapid and even temper-
ature increase of all engine parts during warmup.
Figure7a showsanexplodedview ofthewater pump.
Ventilation for radiator cooled models requires an
inlet opening for fresh air and an outlet opening for
heated air to prevent recirculation of heatedair. The
openingsshould be at least the size of the radiator.
An expansion area in the closed cooling
system maintains proper coolant level by
preventing overflowand
loss of coolant when engine heats up.
The engine water pump is a centrifugal type with a
cast impeller.
It mounts on the front of the engine
cylinder block and is driven by the fan belt from the
crankshaftpulley.The inletto thewater pumpisfrom
the radiator lower hose. The outlet is through the
water pump housing into the cylinder water jacket
passages.
Thewater pump requiresnolubrication; thebearings
are permanently sealed and packed with a lifetime
lubricant. It requires no maintenance other than
bearing replacement if they show excessive
looseness, or replacementof theseal (impeller) ifthe
pump leaks water.
ANTI-FREEZE AND PRESSURE CAPS
Corrosioncan shorten anengine's life bypluggingup
radiator.cores, building uparound hot spotsnearthe
exhaustvalves, and settling inlowareasoftheblock.
Thecorrosivesedimentinsulatesagainst proper heat
transfer and holds heat in. Mostofthe metalsused
in
coolingsystems aresusceptibletocorrosiondamage
that causes coolant leaksandthetemperaturetorise
above safe, normal limits. Since pressurized cooling
systems runfar hotter than the boilingpointof water
(212°F [lOO"C]) at atmospheric pressure, even
greaterbreakdown
of anti-freeze and watersolutions
result. The average pressure cap
(15 pound
[103.5 kPa]) raises the boiling point of the engine
coolant to 265OF (132" C).
Most anti-freeze manufacturers recommend a
minimum50-50 mixofethyleneglycolanti-freezeand
water forwinter and summer inclosedwater systems
withacompletechangeevery yearto avoidcorrosion
and moreexpensivedamage.
Defective pressure caps cause many cooling
problemsand should be replacedevery two years
or
whenever they malfunction.
13

COOLING SYSTEM MAINTENANCE
The cooling system includingthe block and radiator
should be cleaned and flushed at least once a year.
This isespecially true incold weather conditions or
when preparing unit for extended storage (over
30
days or more)!
Thecoolingsystemcanworkefficientlyonly when itis
clean. Scaleandrustinthecoolingsystemslowdown
heat absorption and restrict water flow.
Thethermostat iscalibratedto open at 15OoFf2OF.It
should bechecked also.
An appropriate anti-freeze mixtureshould beusedin
colder climates as necessary.
Corrosion inhibitors reducetheformation of rust ina
cooling system. Corrosion protection can best be
providedinwinter byusinganti-freeze containingthe
inhibitor.
Waterfilters should be usedinareas where thewater
is extremely hard and rust inhibitors cannot protect
the cooling system from the formation of rust and
scale.
Keepthe radiator cleantoprovide maximum cooling.
Removeall dirt, lint, etc. Keepthe radiator cap closed
during operation.
Check the fan belt tension periodically. For proper
operation of the water pump, the fan belt should be
tight enough to prevent slipping.
Check the water pumpfor wear periodically. Loosen
the fan belt and movethe fan and water pump pulley
back and forth.
If wear is excessive, replace the
bearing.
DRAINING COOLING SYSTEM
Whenever draining the cooling system for changing
anti-freeze solution or for out-of-service protection
when only water is used, be sure to open all drains
and hoseconnections wherewater could betrapped.
The following drain plugs must be removed to allow
complete flushing of the cooling system.
Radiator: One petcock lower right front corner.
Engine Block: One drain plug left front near water
pump.
Water Pumps: One drain plug under cover or by
loosening cover.
If an optionalwaterjacket tankheaterisuseditshould bedrained
andflushedalso.Thelowerhosemust bedisconnectedatthetank
heater. Thereis no drain plug.
‘
Further information concerning the locationand part
numbers for the various drain plugs throughout the
unit isshown inthe Parts Catalog.
Onan recommendsthe use of clean ethyleneglycol
anti-freeze solutions inclosed cooling systems dur-
ing normal operation and storage periods. Be sure
anti-freeze solution will protect the cooling system
duringthe coldestwinter weather.
FLUSHING SYSTEM
Flushthesystemat leastonceayear andmoreoften if
operationindicatescloggedpassagesoroverheating.
To flush the system:
1. Drain the radiator, cylinder block and exhaust
manifold.
2. Remove the inlet and outlet hoses between the
engine and radiator.
3. Close all drain plugs and attach the flushing gun
nozzle to the water outlet, as near the exhaust
manifoldaspractical. Restrictthe normalinletline
opening until the system fills with water, then
apply air pressure gradually. Repeatthe process
untilthewater fromthecylinder blockflows clean.
4. Removeflushing gun.
5. Reinstallthermostats, hoses and drain plugsand
refill the system with the proper coolant.
6. When flushing is completed, check the system
thoroughly for any leaks uncovered bythe clean-
ingoperations.
BLEEDINGAIR FROM COOLING SYSTEM
Air must be bledfrom the cooling system for proper
operation.
If your engine is not equipped with a vent
plug in the water pump housing, install a
3/8” pipe
plug inthe top of the housing. Allow engine to cool
and bleed as follows:
1. Fillradiatorwith 50-50 mixofethyleneglycolanti-
freeze and water.
2. Remove plug or sender from water manifold on
top of engine to vent trapped air (Figure 7b).
Replaceplugorsender whenwateremergesfrom
hole.
14

3. Remove plug on top of water pump housing to
4- After thermostat has opened completely, remove
vent trapped air (Figure
7b). Replace plugwhen
water emergesfrom hole.
it fromhotwaterandallow it tocoolinsurrounding
air. The thermostat should close within
a short
time.
4. Fill radiator to proper level.
TEST1 NG THERMOSTAT
If a sticking or faulty thermostat issuspected, test as
follows:
1. Removethermostat from cylinder head.
2. Heat a pan of water to approximately 150°F.
Checktemperatureusingathermometerimmersed
inwater.
3. With thermostat suspended in water at temper-
ature of
1 5OoF,thermostat shouldstart to open.
5. If the thermostat sticks or does not operate
6. Always install a new gasket when replacing the
properly, replaceitwith a new one.
thermostat.
REPAIR
After makingrepairsonthecoolingsystem,tightenall
connections thoroughly. Use Permatex or thread
sealing compound on all threaded connections to
prevent leaks or the entry of air into the system.
Read instructions on PermatexSealercan before applying sealer
to engine parts.
WATER MANIFOLD
PLUG OR SENDER
\ WATER PUMP
W
cs-1361
FIGURE 7b. BLEEDING COOLING SYSTEM
15

FUEL SYSTEM
KEEP FUEL
CLEAN!
0
DIRTY FUEL IS ONE OF THE MAJOR CAUSES OF
ENGINE FAILURI
0
REMEMBER- EVEN A TINY PARTICAL OF DIRT IN
THE INJECTION SYSTEM MAY STOP YOUR ENGINE!
0
FUEL MANAGEMENT FUEL SYSTEM
1.
2.
3.
4.
5.
Zinc or galvanized tanks should not be used as
harmful compounds may form due to reactions
with fuel oil impurities.
Pitch fuel tanks down away from fuel outlet.
The fuel system (Figure 10) consists of a glass
sediment bowl, fuel transfer pump, primary filter,
secondary filter, injection pump, injectors, and the
connecting fuel lk~es.
Use a drain cock with provisionsfor draining off
water and sediment.
A fuelfilterandwatertrap locatedontankoutlet is
good practice.
Fill tanks on mobileequipmentat end of eachday
to keep condensationat a minimum.
In low temperatures, it is quite commonfordieselfuels to become
jelly-like. The pointat which they cease beingaliquid
is known as
the pour point. This quality should be watched carefully in
temperatures of
20°F (-7°C) or lower.
Pour Point' Pourpoint indicatesthesuitability of fuel
to cold weather operation. Fuel should pourat 10°F
(-6°C) below the lowest expected ambient
temperature, Figure
8. .
INJECTION
GLOW NOZZLE
PLUG
. CONNECTION
POINT FOR
FUELRETURN
SECONDARY
FUEL FILTER
FUELFILTER
FIGURE 10. FUEL SYSTEM
FIGURE 8. POUR POINT
16

Do not use galvanized lines, fittings, or fuel
tanks in underground portions of the fuel
system. Hazardous fuel leaks may be caused by electrolytic
corrosion from moisture and chemicalsin the
soil (galvanism).
Some safety ordinancesprohibitthe useof galvanizedmaterialsin
fuel systems and the use of threaded cast ironfittings as well.
The fuel system, located on the service side of the
engine, usesa transfer pump to deliver fuel from the
tank to a high pressure injectionpumpatabout
12 to
14 psi (83-97 kPa). The injection linesdeliver fuel to
the injectors at high pressure and act as fuel dis-
tributors to the injectors. The time interval between
individual injectors is varied in the pump by engine
speed. From the injection pump, metered fuel is
forced through adelivery valvetotheinjector linesat
about 1900 psi (13,110 kPa). When the cylinder air
reaches about 1000°F (538°C) on the compression
stroke, the injector sprays fuel into the hot com-
pressed air where
it ignites. The delivery valve inthe
injection pump and a pintle valve in the injector
assists the precision timed injection of fuel into the
cylinder.
.
Excessfuel is returnedtothetank aftereachinjection
cyclebyafuel return linefrom thenozzle. An adapter
combines the leak-off fuel with theflow-through fuel
from the injection pump. A return line connected at
this point returns the combined fuel back tothefuel
supply tank.
Adieselenginecannottoleratedirtinthefuel
svstem. Itisoneof themaiorcausesof diesel
engine failure. A tiny piece
of dirtintheInjectionsystemmaystop
your unit. When opening any part
of the fuel system beyondthe
secondaryfuel filter, placeall partsin
a panof cleandieselfuelas
they are removed. Beforeinstallingnew or used parts,flush them
thoroughly, and installwhile still wet.
FILTER SYSTEM
The sediment bowl has a fine mesh screen which
blocks dirt and water entry into the transfer pump,
Figure 10. Thedirtandwater remaininthesediment
bowl which should be removed for cleaning as
required. The primary and secondary fuel filters are
replaceable spin-on units that clean the fuel of
extremely fineparticles beforeitgoestotheinjection
pump.
These filters are mounted
on a common casting
which bolts to the oil fill tube. Positive filtration is
assured because the engine won’t run when either
filter is loose
or missing.
Average pore size of the second filter is
.0005
(0.0127 mm) smaller than the first filter. This means
most particles escaping the first filter are trapped in
the second filter.
Water in Fuel Filters: Drain water periodically as
required frombothfilters. Replaceprimaryfilterevery
600 hours and secondary filter every 3000 hours.
When replacing filter, tighten screw until gaskets
touch base, then tighten screw
1 to 1-1/2 turns.
FUELTANK AND LINES
Where a separate fuel tank is used, install so the
vertical distance from bottom of the tank to the fuel
pump does notexceed six feet. Auxiliary fuel pumps
are available to provide an additional eight-foot lift.
Avoid gravity feed of fuel to the engine. Provide a
siphon break if tank is above pump. When sharing a
fuel tank, donotconnect toan existing lineata point
above the fuel supply level.
Thesediesel engines require a fuel supply lineanda
separate return line. Install the fuel supply linefrom
tank to the 1/8-inch pipe inlet in the fuel pump.
Connect fuel return line to fitting at injection pump.
See Figure
10. Useapproved flexible fuel linesatthe
engine to absorb vibration. Be sure there are no air
leaks inthe suction line.
Install a shut-off valve in the tank for service con-
venience.
FUEL TRANSFER PUMP
The fuel transfer pump (Figure ll), is a diaphragm
andcheckvalvetypepumpoperated
by acamlobeon
the engine camshaft. The pump cam follower has a
wide surface to prevent wear as it rides on the
camshaft lobe. The priming lever is manually
operated to primeand bleed the system.
The diaphrgam spring maintains required fuel
pressureto the injection pump. Fuelpressureshould
be12-14psi(83-97 kPa)whenoperatingat1800rpm.
ROCKER ARM
SPRING ...
COVER
DIAPHRAGM
ASSEMBLY
DIAPHRAGM
SPRING
ROCKER ARM
LINK
FIGURE 11. FUELTRANSFER PUMP
17

Fuelpumppressure may becheckedbyconnectinga
pressure gauge and tee at the fuel outlet. A vacuum
the pumphasenough capacityto liftfuel about
6 feet
(1.83 m). The fuel pump should produce 15
to 18
inches (381to
457 mm) of vacuum at sea level.
7. Tighten cover screws alternately and securely,
then release rocker arm.
test.
gauge connected at the fuelinlet will show whether
8. Install pump on the engine and repeat pressure
INJECTION NOZZLES
.1.
2.
3.
4.
5.
6.
7.
Onan diesel engines use hydraulically-operated,
pintle-type injection nozzles, Figure
12. They are
factory adjustedtoopenat 1900to1950
psi (13,110 to
13.455 kPal. However.afterseveralhundredhours
of
Fuel Pump Removal Disassembly
RemovePump inlet and outlet lines. Removetwo
capscrews holding pumptoengineand
lift itoff.
Notchthe pumpcover andbodywithafilesothey
can be reassembled in same relative positions
and remove six screws holding them together.
operation (he nozzlepressurewill decrease to about
1750 psi (12,075 kPa).
Tao bodv with a screwdriver to seDarate two
COVER
paits. Ddnotpry them apart; this would damage
diaphragm.
Remove screws holding valve plateto coverand
lift out valve and cage assemblies.
Drive out rocker arm hinge pin.
Remove rocker arm, spring and link.
Lift out diaphragm assembly and diaphragm
spring.
Repair: Transfer pump failure is usually due to a
leakingdiaphragm,valve orvalvegasket, Figure11.A
kit is available for replacement of these parts.
Becausetheextent of wear cannot bedetectedbythe
eye, replace all parts in the kit. If the diaphragm is
broken, or leaks,check for diluted crankcase oil and
replace.
Occasionally,failure isduetoabrokenorweakspring
or wear inthe linkage. Inthis case, replacethe worn
partsor installanewpump. Obtainreplacement parts
other than the repair kit from an original equipment
parts distributor.
Assembly:
1. When installing a new diaphragm, soak it infuel
before assembling. Insert diaphragm spring and
soaked diaphragm into pump body.
2. Insert link and rocker arm into body and hook it
over diaphragm pull rod. Align rocker arm with
-rockerarm pin hole and drive in pin.The priming
levermust be
in positionshown in Figure 11 when
installing rocker arm.
3. Compress rocker spring and install between the
body and rocker arm.
4. Insertvalve cages, gaskets and valve cover plate.
Position inlet valve with spring showing and
outlet valve with spring in cover recess.
5. Assemble cover to body with notch marks lined
up. Install screws, but do not tighten.
6. Push rocker arm in full stroke and hold in this
position to flex diaphragm.
PRESSURE A
GASKET^
SPINDLE ASSEMBLY: ADAPTER
-
NOZZLEGASKET
NOZZLE SHIELD
SHIELD CASK NOZZLEASSEMBLY
FUELCUP GASKE
CYLINDER HEAD
-
A00
FIGURE 12. NOZZLE ASSEMBLY
COVER 4
SCREW -+
FUEL INLET A
NOZZLE
PRESSURE
ADJUSTING ;ING
JDLE
rDAP'
ASS
TER
4BLY
The diaphragmmust be flexed, orit will delivertoomuch fuel
pressure. FIGURE
13. INJECTOR NOZZLE HOLDER
18