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Summary of Contents for RDJC

Page 1: ...Service Manual Diesel Engines 9 84 Printed in U S A Redistribution or publication of this document by any means is strictly prohibited...

Page 2: ...dequatelysecured 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 brittle enough to break Bes...

Page 3: ...4 Cooling System 16 Fuel System 22 Oil System 36 Governor System 39 StartingSystem 41 Engine Disassembly 48 Control System 59 INCORRECT SERVICE OR REPLACEMENT OF PARTS MIGHT RESULT IN SEVERE PERSONNAL...

Page 4: ...iews of each assembly the indi vidual piece part numbers and their proper names for ordering replacement parts Use only Genuine Onan replacement partsto ensure quality and the best possible repair and...

Page 5: ...3 Crankshaft Rotation Governor Adjustable Mechanical Valve Clearance Cold viewed from flywheel Clockwise Clockwise Intake in 0 011 0 017 mm 0 279 0 432 Exhaust in 0 016 0 017 mm 0 406 0 432 Oil Filte...

Page 6: ...127 Maximum Allowable Out of Round 0 001 0 025 Main Bearing Journal Diameter 2 2427 2 2435 56 965 56 985 Front and Rear Main Bearing Clearance Original 0030 0043 076 109 Center Main Bearing Clearance...

Page 7: ...8 11 8872 Bore Diameter 1 361 1 362 34 570 34 595 Insert Outside Diameter 1 364 1 365 34 6456 34 6710 Seat Width 047 062 1 19 1 57 Angle 45 Available Insert Oversizes 002 0508 VALVE EXH AUST VALVE GUI...

Page 8: ...est Fixture 420 0322 Combination Main and Cam Bearing Driver 420 0326 Diesel Compression Tester 420 0283 Valve Spring Compressor Tool 420 0119 Valve Seat Remover 420 0311 Flywheel Puller 420 0100 Cran...

Page 9: ...Governor Adjustment High Spring Sensitivity Incorrectly Installed Governor Yoke 01 Cup lnrufflclent Coolanl FauIw Thermosrat Warn Water Pump or Defective Seals Water Passages Restrimed Blawn Head Gask...

Page 10: ...ge 11for recommended oil change intervals and procedures WARNING Crankcasepressure couldblow out m hot oil and cause serious burns Do NOT check oil while the engine is operating Recommended Fuel Use A...

Page 11: ...ntil engine comes up to speed To START 4 5 1 2 PREHEAT COLD ENGINE PUSH PREHEATSWITCH AND HOLD 30 SECONDS IF ABOVE 55 F 13 C 60 SECONDS IF BELOW 55 F 13 C NEVER PREHEAT MORE THAN 60 SECONDS steps 1 2...

Page 12: ...t least 20 seconds before cranking occurs The time delay relay prevents immediate engagement of the starter incasethe load is reapplied beforethe engine stops APPLYING LOAD If practicable allow engine...

Page 13: ...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 1...

Page 14: ...ings inthe1 2 inch 12 70 mm pipe tapped oil drain hole in the base Crankcasepressure couid biowout hot oil and cause serious burns Do NOT check oil while the engine is operating CAP AND OIL LEVEL HIS...

Page 15: ...rance of mois ture bugs dirt etc Cleanandwipe entire unit Coat partssusceptible to rust with a light coat of grease or oil Disconnect battery and follow standard battery storage procedure glow plugs 3...

Page 16: ...ut away from the operator Using a resonator in addition to a muffler Avoiding use of flexible lines The importance of exhaust systems normally supplied by the customer cannot be over emphasized A poor...

Page 17: ...27 3 8 1 2 47 5 2 1 58 6 8 2 07 17 5 18 SINGLE THIMBLE DIAMETER DOUBLE VENTILATED THIMBLE DIAMETER 6 I52mm LARGER THAN EXHAUST LINE I O S mm LARGER OR s IN END SLEEVE EXHAUST LINE PASSING THROUGH II W...

Page 18: ...f switch is not a normal condition Examine the cooling system to determine the cause of the overheating and repair as required 16 COOLING SYSTEM MAINTENANCE The cooling system including the block and...

Page 19: ...sticks or does not operate prop erly replace it with a new one 6 Always install a new gasket when replacing the thermostat Draining Cooling System Whenever draining the cooling system for changing an...

Page 20: ...operating temperature the thermostat opens This permits heated water to flow into the radiator to be cooled Recirculation ensures both rapid and even tempera ture increase of all engine parts during...

Page 21: ...to cool the generator and support combustion for the engine HIGH WATER TEMPERATURE Check the thermostat opening and closing with the thermostat immersed inawater bath Thethermostat should start to ope...

Page 22: ...pro tected from corrosion by a zinc pencil mounted on a pipe plug in one end of the heat exchanger Inspect the pencil at least every two months and replace if deteriorated to less than one half origin...

Page 23: ...ch as bearings seals wear face and impeller and use a new cover gasket Assembly sequence is the reverseof the dis assembly procedure After the pump has been assembled seeFigure7d the impeller B must b...

Page 24: ...ious engine damage KEEP FUEL CLEAN 0 DIRTY FUEL IS O N E O F THE M A J O R CAUSES O F E N G I N E FAILURE 0 REMEMBER E V E N A T I N Y PARTICAL OF DIRT IN THE INJECTION SYSTEM M A Y STOP Y O U R ENGIN...

Page 25: ...replaceable unitsthat clean the fuel of extremely fine particles before it goes to the injection pump These filters are mounted on a common casting which bolts to the oil fill tube Positive filtratio...

Page 26: ...cause crankcase oil leakage If this is the case the pump should be replaced 1 2 3 4 5 6 7 When installing a new diaphragm soak it in fuel before assembling Insert diaphragm spring and soaked diaphragm...

Page 27: ...istorted or the nozzle drips before it reaches opening pressure it is defective and must be cleaned or replaced Cleaning is the most important part of nozzlemaintenance Make sure the work area and equ...

Page 28: ...valve seat 2 After scraping the carbon polish the valve seat by using a round pointed stick dipped in tallow Polishing should restore seat to its original finish unless it s scored 4 Clean nozzle valv...

Page 29: ...ing Then remove centering sleeve to prevent it from binding between nozzle and cap nut Tighten nozzle cap nut to 50 55 ft lb 68 75 Nom A dirty mounting surface could permit blow by causing nozzle fail...

Page 30: ...of fuel under high pressure to the injection nozzles A constantbleedcheckvalveisfurnishedwithallPSUpumps The bleed valve automatically bleeds off a restrictedamount of fuel fuelvapors andsmallquantiti...

Page 31: ...ansmits motion from the tappet to the plunger and adjusts plunger timing for the fuel pumped to each injector during operation Plunger reciprocation and rotation are so phased that only one fuel injec...

Page 32: ...ck Forcing the plunger or gear willdamage thepump Dissolvepreservative by soak ing pump in clean filtered diesel fuel for 75 to 30 minutes TIMING BUTTON CODE The timing button has a code number or let...

Page 33: ...s codeshould bethe sameas the code number stamped on injection pump Figure 23 CAUT ON OnallPSUpumpsbesureto rn hold the pump drive gear securely to the pump body when removing the tappet If not the pu...

Page 34: ...L N FLEXIBLE LINE PUMP uA b 4 2 1 FIGURE 26 FUEL LINE TO INJECTORS 5 Rotate flywheel clockwise when facing front of engine Figure 271 to point where PC mark on flywheel is about 15 degrees 1 25 to 1 5...

Page 35: ...ment 3 x 003 009 3 x 076 229 mm Since 0 1 inch 2 54 mm equals 003 inch 076 mm in button thickness the installed button is too thin by 009 inch 0 229 mm This means a button 009inch 0 229 mm thickerthan...

Page 36: ...take lobe points outward and down 45 degrees 2 Remove screw Figure 30 on side of injection pump Rotate drive gear until a 0 125 inch 3 175 mrn brass rodcan beinsertedintodrive gearslot This locks the...

Page 37: ...for firing the injectors SPRING DELIVERY VALVE SEAT INE PRESSURE FIGURE 32 DELIVERY VALVE CLOSED PLUNGER DOWN BLEEDING FUEL SYSTEM Bleedfuel systemwheneverthefilters arechanged or when there is air i...

Page 38: ...and is driven by the crankshaft Except for the gaskets component parts of the pump The pump draws oil from the crankcase anddelivers it through the oil filter to the rocker housing drillings through t...

Page 39: ...th 2 5 16 inches 1 16 inch 74 613 1 588 mm 2 225 Ib 0 11 Ib at 1 3 16 inches compressed 1 01 kg 0 05 kg at 30 163 mm compressed CYL HEAD 3 AND 4 REAR BEARING OIL BYPASS OIL BYPASS FIGURE 37 BYPASS VAL...

Page 40: ...lacement every200 hoursof normal operation Removefilter by turning counterclockwise using a filter wrench Install new filter finger tight plus 1 4 to 1 2 turn rW Hot crankcase oil can causeburns if it...

Page 41: ...varythenumberof effective coils for getting the desired sensitivity the speed drop from no load to full load 8435 Maintenance The linkage must be able to move freely through its entire travel Periodic...

Page 42: ...T COUNTERCLOCKWISE TO DECREASE SPEED adjusting ratchet accessible through a covered GOVERNOR SPRING access hole on the side of the blower housing NUT sensitivity more speed drop If the governor is too...

Page 43: ...gravity should be between 1 290 and 1 225 when 75 percent charged If not rechargethe battery Check electrolyte level If battery will not recharge replace it Keep battery connections tight and clean Wi...

Page 44: ...lathe Field Coils Using a test lamp and probes check the field coils for grounding to the motor frame or open circuit Inspect all connections to be sure they are properly clinched and soldered Inspect...

Page 45: ...empt to disassemble clutch assembly 8 If necessaryto service solenoid removefour cap screws and electrical connection holding it to motor frame Remove two screws on rear of solenoid to reach switch co...

Page 46: ...tery cable and wires to starter 6 Connect battery cables to battery Connect ground cable last connect ground cable first from starter starter to mounting bracket MlTSUBlSHl STARTER DISASSEMBLY 1 Remov...

Page 47: ...MlTSUBlSHl STARTER ASSEMBLY CLUTCH SNAP RING PINION GEAR 1 Forassemblyreversethe disassemblyprocedure but note the following items See Figure 47d I Whenever starter motor isdisassembledapply grease to...

Page 48: ...STALLATION Pinion Gap Adjustment After assembling starter motor adjust pinion gap 1 Remove M terminal nut and wire from solenoid 2 Connect positiveterminal of batteryto S terminal on solenoid and nega...

Page 49: ...rush assembly as follows 1 Connect an ohmmeter or test lamp 12 volts to the field terminal and to the bracket The test lampshould not light or resistancereadingshould be high infinite If not there is...

Page 50: ...ade used in crankcase Duringfirst few critical momentsof operation the engine will depend on this lubrication 5 After you haveinternal engine partsreassembled the engine should turn freely If reasonab...

Page 51: ...or complete customer satisfaction repaint unit Onan Green spray can 525 0137 or Onan White spray can 525 0216 and apply instructionsfrom Kit 98 11OOC or Marine Kit 98 1807 CYLINDER HEADS VALVES Each c...

Page 52: ...ion test can be used to deter mine the condition of valves pistons piston rings and cylinders To check compression run the engine until thor oughly warm Stop engine and remove all injection nozzles In...

Page 53: ...head bolts in sequence to 44 46 foot pounds 60 62 Nom This step compensates for the com press of the cylinder gasket Push a valve seat stem oil seal onto each intake valve guide and clamp in place The...

Page 54: ...n break it using a cold chisel and heavy hammer To install a new ringgear place itinanoven heatedto 380 F 400 F 192 to 204 C for 30 to 40 minutes Do not heat witha torch orringgear may be warped When...

Page 55: ...SNAP GOVERNOR U FIGURE 54 GOVERNOR CUP Repair Replace any flyballs that have flat spots or grooves The flyball spacer is attached to the cam shaft gear with three flathead screws Check to see that th...

Page 56: ...ton pin and just below the oil control ring Clear ance should be 0 0055 inch to 0 0075 inch 0 140 to 0 191 mm If not replace the piston and check the cylinder for possible reconditioning CAST RON O I...

Page 57: ...The camshaft is a one piece machine casting driven through gears by the crankshaft It rides on sleeve bearings pressed into the crankcase In addition to providing a means of opening and closing the va...

Page 58: ...haft Assembly 1 Install key and press camshaft gear on camshaft until it bottoms on flange with no clearance 2 Install governor components 3 Slide thrust washer onto shaft Measurecamshaft end play it...

Page 59: ...ts In addition to machining the crankshaft must be shot peened and super finished cause early failure When the shaft is machined follow this data and Figure62to shotpeen each crank pin fillet b I Fail...

Page 60: ...installed or the bearing plate shims and gaskets to provide 0 010 cylinder refinished the engine must be run in before inch 0 254 mm to 0 015 inch 0 381 mm end regular operation can be resumed Runthe...

Page 61: ...are not supplied r ith the engines In most cases the engines are used for F MAINTENANCE Periodicallycheck all connectionsand contacts inthe control system to be sure they are tight and clean PRE HEAT...

Page 62: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 63: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 64: ...e N E Minneapolis MN55432 612 574 5000 InternationalUse Telex 275477 Fax 612 574 8087 Onanis a registeredtrademark of OnanCorporation 1 800 888 ONAN Redistribution or publication of this document by a...

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