Onan RDJE Service Manual Download Page 51 | Manualshive

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Summary of Contents for RDJE

Page 1: ...Service Diesel Engines 974 0250 SPEC A 10 88 Printed in U S A...

Page 2: ...els are highly flammable Fuel lines 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 c...

Page 3: ...ols 5 Engine Troubleshooting 6 Service and Maintenance 7 Exhaust System 11 Cooling System 13 FuelSystem 16 Governor System 33 Starting System 35 Engine Disassembly 42 ControlSystem 54 Oilsystem 30 TO...

Page 4: ...Pump gear type yes Oil Filter full flow yes Oil Capacity U S quarts includes Filter 3 2 84litre Exhaust Connections pipe tapped 1 1 2 38 1mm Shaft Length 4 101 6mm Keyway Length 3 76 2mm Keyway Width...

Page 5: ...030 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 Bo...

Page 6: ...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 Insert Outside Diameter 1 364 1 365 34 6...

Page 7: ...l guide and driver 420 0456 Nozzle centering sleeve 420 0321 Diesel nozzle tester 420 0322 Combination main and cam bearing driver 420 0326 Diesel compression tester 420 0283 Valve spring compressor t...

Page 8: ...ENGINE TROUBLESHOOTING 6...

Page 9: ...not be compatible when mixed together Never remove 011 level Indicatorcap with the engine running because oil will blow out of the tube causing possible injury Recommended Fuel Although number 2 dies...

Page 10: ...SE 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 in the following sequence 1 One half hou...

Page 11: ...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 base and...

Page 12: ...FILTER CHANGE Place pan under old filter and remove by turning counterclockwise Clean filter mounting area Lubricate gasket on newfilter with oil and screw filter on clockwise until gasket touches mou...

Page 13: ...ble leaks Report any ex hausthazardstotheowner operatorandwarnthemof thepotential dangers to life if not repaired INSTALLATION TIPS Points to remember when installing an exhaust system are Exhaust pip...

Page 14: ...PIPE FITTINGSAT POINT OF RISE DRAIN CONDENSATIONTRAP PERIODICALLY A617 FIGURE 5 CONDENSATION TRAP WARNING ENGINE EXHAUST GAS CARBON MONOXIDE IS DEADLY Carbon monoxide is an odorless colorless gas form...

Page 15: ...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 inlet t...

Page 16: ...in plug left front near water pump Water Pumps One drain plug under cover or by loosening cover If an optionalwater jacket tank heateris usedit should bedrained andflushedalso The lowerhosemust bedisc...

Page 17: ...Checktemperature usingathermometer immersed in water 3 With thermostat suspended in water at temper ature of 15OoF thermostat should start to open 5 If the thermostat sticks or does not operate 6 Alwa...

Page 18: ...a drain cock with provisionsfor draining off water and sediment A fuel filterand watertrap located ontankoutlet is good practice Fill tanks on mobile equipment at end of each day to keep condensation...

Page 19: ...be removed for cleaning as required The primary and secondary fuel filters are replaceable spin on units that clean the fuel of extremely fine particles before it goesto the injection pump These filt...

Page 20: ...iaphragm valve or valve gasket Figure11 A kit is available for replacement of these parts Becausethe extent of wear cannot bedetected bythe eye replace all parts in the kit If the diaphragm is broken...

Page 21: ...the cap nut over the adjusting screw of each Install the nozzle to be tested on astaticfuel nozzletestingfixture maybe purchasedfrom Onan Followingthe instructions on the tester adjust the opening pre...

Page 22: ...gallery The hooked end of scraper is inserted into the gallery and then carefully rotated 6 Examine nozzlevalve and body with a magnifying glass If erosion and scoring conditions are found renew the...

Page 23: ...ing between nozzle and cap nut 5 Adjust to specified torque NOZZLE 1NSTALLATI0N Before installing the injection nozzles in the engine thoroughly clean each mounting recess A dirty mounting surface cou...

Page 24: ...rated by the engine camshaft They deliver an accurately measured quantity of fuel under high pressure to the injection nozzles A constantbleed checkvalve isfurnishedwith all PSUpumps The bleedvalveaut...

Page 25: ...tappet to the plunger and adjusts plunger timing for the fuel pumped to each injector during operation Plunger reciprocationand rotation are so phased that only one fuel injector is served during thea...

Page 26: ...re to holdthe pump drivesecurelyto the pump bodywhen removing thetappet Figure 24 If not the pump will come apart and bedifficult to reassemble Also the meteringsleeve may drop off the plunger into th...

Page 27: ...r a new or replacementpump is as follows 1 Remove old pump 2 Determine total pump flange and button thickness for old pump a Write down dimension given on old pump flange See Example Inches mm Port cl...

Page 28: ...the 1 8 inch 3 18 mm brass rod position the pump in the hole Figure 29 and firmly apply pressure The arr0 w on Figure 29 shows the position of the injection pump cam and gear on the camshaft A slight...

Page 29: ...hout recording the PC dimension and the timing button thickness it is necessary toflow time the pumpto establish the exact PC position 1 Install No 12 timing button in PSU pump as previously discussed...

Page 30: ...he PC mark on the flywheel aligns with the timing pointer Ifit doesn t match timing is either early or late and another timing button is required Figure 35 FIGURE35 PORT CLOSING PC MEASUREMENT Procedu...

Page 31: ...pumpuntil air bubbles are all out and clear fuel flows from the bleed valve automatically Figure 37 If the transfer pump camlobeis on the highside the priminglever will not operate the pump Rotate the...

Page 32: ...kcase anddeliversit through the oil filter to the rocker housing drillings through the crankcase to the crankshaft bearings camshaft front bearing crankshaft passages to con necting rod bearings and c...

Page 33: ...n adjustable and normally needs no maintenance To determine if high oil pressure is caused by the plunger sticking closed or low oil pressure by the plunger sticking open clean and inspect the valve T...

Page 34: ...s of normaloperation Removefilterby turning counterclockwise usingafilter wrench Install new filter finger tight plus 1 4 to 1 2 turn FIGURE 41 FULL FLOW OIL FILTER The RDJE crankcase breather has a v...

Page 35: ...theball joints with graphite or light non gumming oil Also inspect the linkage for binding excessive slack and wear Testing and Repaie Removing the gear cover for access to the governor cup and other...

Page 36: ...the blower housing sensitivity more speed drop If the governor is too Counterclockwise gives more sensitivity less speed drop when full load is applied clockwise gives less sensitive a rapid hunting c...

Page 37: ...er Specific gravity should be between 1 290 and 1 225 when 75 percent charged If not rechargethebattery Check electrolyte level If battery will not recharge replace it Keep battery connections tight a...

Page 38: ...n for evidences of damage The only way to check for field coil shorts is to use the starting motor test Brushes Check the brushes for wear or improper seating They should slide freely in their holders...

Page 39: ...yto service solenoid remove four cap screws and electrical connection holding it to motor frame Remove two screws on rear of solenoid to reach switch contacts If necessary to remove starting motor fla...

Page 40: ...able and wires to starter 6 Connect battery cables to battery Connect ground cable last MlTSUBlSHl STARTER DISASSEMBLY connect ground cable first from starter starter to mounting bracket 1 Remove M te...

Page 41: ...l STARTER ASSEMBLY XES1255 FIGURE 49d MlTSUBlSHlSTARTER Forassembly reversethe disassemblyprocedure but note the following items See Figure 49d Whenever starter motor isdisassembledapply grease to eac...

Page 42: ...ION GEAR INSTALLATION Lever Assembly Installation Figure499 showsthe correct methodof installingthe lever assembly spring and packing Pay close attention to direction of lever PACKING LEVER I CENTER B...

Page 43: ...r and gasket Brush Assembly Tests Test brush assembly as follows 1 Connect an ohmmeter or test lamp 12 volts to the field terminal andto the bracket Thetest lamp shouldn t light or resistance reading...

Page 44: ...oat it heavily with oil same grade used in crankcase During first few critical momentsof operation the engine will depend on this lubrication 5 Xferyou haveinfernalengi nepzrfsEiGembTed the engine sho...

Page 45: ...onnections ADJUSTMENTS Adjust governor for speed and sensitivity IMPORTANT For complete customer satisfaction repaint unit Onan Green spray can 525 0137 or Onan White spray can 525 0216 and apply inst...

Page 46: ...e in compression with oil in the cylinder indicates piston blow by Keep rockerarms rockerarmnuts push rodsandtappetsinorder so they go back in the same valve train position 1 Remove rocker box cover f...

Page 47: ...s ends out of square CYLINDER HEAD GASKET SEALANT The cylinder head gaskets on 2 cylinder water cooled RDJ series diesel engines require a Room Temperature Vulcanizing RTV Sealant around the water pas...

Page 48: ...ghten the cylinder head bolts and checkvalve clearanceor the headgasketsmay beblownout FIGURE 54 HEAD BOLT TORQUE SEQUENCE Use Never Seez Fel Pro C5 A or equivalent thread lubricant when installing cy...

Page 49: ...chisel and heavy hammer To install a new ringgear placeitinanovenheatedto 380 F 400 F 192 to 204 C for 30 to 40 minutes Do not heat with a torch or ring gear may be warped When heated properly the rin...

Page 50: ...or cup WHEN GOVERNOR IS CAM SHAFT CENTER PIN GOVERNOR CUP GOVERNOR FLY BAL FIGURE 57 GOVERNOR CUP Repair Replace any flyballs that have flat spots or grooves Replace the cup if the race surface is gro...

Page 51: ...piston and check the cylinder for possible reconditioning PISTON PINS Each piston pin should be a thumb push fit into its piston at room temperatures If the pin is excessively loose install a new one...

Page 52: ...n ing sequence 10 Replace oil CAMSHAFT The camshaft is a one piece machinecasting driven through gears by the crankshaft It rides on sleeve bearings pressed into the crankcase In addition to providing...

Page 53: ...at its center Installation Camshaft 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 sha...

Page 54: ...t is machined follow this data andFigure 65 to shotpeeneach crank pin fillet 3 16 4 763 mrn H E s T O B E S H O T S U R F A C E S P E E N A II I L z ZZ J T O E E M A S K E D _ 1IT H I S A R E A D U R...

Page 55: ...ets Of more than 0 01 inch steel shim Of proper thickness and a thin gasket on each side of shim This avoids excessive gasket compression and maintains bolt torque BREAK IN PERIOD Whenever new rings o...

Page 56: ...Installation nearly always differs Therefore the manufacturer or fabricator generally provides a control for the complete unit MAINTENANCE Periodically check all connections and contacts inthe control...

Page 57: ......

Page 58: ...Onan Corporation 140073rd Avenue N E Minneapolis MN55432 Telex 275477 Fax 612 574 8087 Onan is a registered trademark of Onan Corporation 612 574 5000...

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