Onan Service Manual DJBA DJB DJC DJE Diesel Engine

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4 f Service DJBA DJB DJC DJE Diesel Engines 967-0751 3-88 Printed in USA. ,

Safety Precautions It is recommended that you read your engine manual and become thoroughly acquainted with your equipment before you start the engine. Fuels, electrical equipment, batteries, exhaust gases and moving parts present potential hazards that could result in serious, personal injury. Take care in following these recommended procedures. ' S8fOty COdW 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 use is at the owner's sole risk. . ' General Provide appropriate fire extinguishers and install them in convenientlocations. Use an extinguisherratedABC by NFPA. Make sure that all fasteners on the engine are secure and accurately torqued. Keep guards in position over fans, driving belts, etc. If It is necessary to makeadjustments whiletheengine is running, use extreme caution when close to hot ex- hausts, moving parts, etc. Protect Against Movlng Parts Do not wear loose clothing in the vicinity of moving parts, such as PTO shafts, flywheels, tilowers, coup- lings, fans, belts, etc. Keep your hands away from moving parts. Batted08 0 Before starting work on the engine. disconnect batteries to prevent inadvertentstarting of the engine. DO NOT SMOKE while servicing batteries. Lead acid batteries give off a highlyexplosivehydrogengas which can be ignited by flame, electricalarcingor by smoking. Verify batterypolaritybeforeconnectingbatterycables. Connect negative cable last. FwI Systom 0 DO NOT fill fuel tanks while engine is runnirlg. DO NOT smoke or use an open flame in the vicinity of the engine or fuel tank. Internal combustion .engine fuels are highly flammable. Fuel lines must be of steel piping, adequately secured. and free from leaks. PiDina at the enaine should be approved flexible me. PO nor use copper piping ror flexible lines as copper will work harden and become brittle enough to break. Be sure all fuel supplies have a positive shutoff valve. b . E Exhrust Systom Exhaust products of any internal combustion engine are toxic andcan cause injury, or death if inhaled. All engine applications, especiallythose within a confined area, should be equipped with an exhaust system to discharge gases to the outside atmosphere. Do not use exhaust gases to heat a.compartment. Make sure that your exhaust system is free of leaks. Ensure that exhaust manifolds are secure and are not warped by bolts unevenly torqued. Exhrust Gas is Dordlyi Exhaust gases contain carbon monoxide, a poisonous gas 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: Dizziness .Vomiting Headache 0 Muscular Twitching Weakness and Sleepiness If you experience any of these symptoms, get out into fresh air immediately, shut down the unit and do not use until it has been inspected. The best protection against carbon monoxide inhalation is proper installationand regular, frequent inspectionsof the complete exhaust system. If you notice a change in the sound or appearance of exhaust system, shut the unit down immediatelyand have It inspected and repairedat once by a competent mechanic. b 'Cooling Systom . 0 Coolants under pressure have a higher boiling point than water. DO NOT open a radiator pressure cap when coolant temperature is above 212OF (100OC) or while engine is running. 0 Throbbing in Temples c Y Kwp the Unlt and SurroundingAroa Clem 0 0 'Make sure that oily rags are not left on or'near the engine. Remove all unnecessary grease and oil from the unit. Accumulatedgrease and oil can cause overheatingand subsequent engine damage and present a potential fire hazard. . E4

Table of Contents c TITLE PAGE General Information .................................................. 2 Specifications ....................................... ..-. .............. 3 Dimensions and Clearances ........................................... 4 Assembly Torques and Special Tools .................................. 6 Engine Troubleshooting ............................................... 7 Service and Maintenance .............................................. 8 Exhaust System ..................................................... 14 Cooling System ...................................................... 16 Fuel System ......................................................... 18 Governor System .................................................... 38 Oil System .......................................................... 40 Starting System ...................................................... 45 Special Equipment ................................................... 67 Control System ...................................................... 68 Wiring Diagram .......... . ' . ........................................... 69 Flywheel Alternator .................................................. 51 EngineDisassembly ................................................. 55 I WARNING INCORRECT SERVICE OR REPLACEMENT OF PARTS MIGHT RESULT IN SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE . SERVICE PERSONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANlCAL SERVICE . I

General Information INTRODUCTION This manual deals with specific mechanical and electrical information needed by engine mechanics for troubleshooting, servicing, repairing, or overhauling the engine. Use the table of contents for a quick reference to the separate engine system sections. Use the separate Parts Catalogs available at the dealer level, for parts identification and for establish- ing their proper location on assemblies.' The troubleshooting guide is provided as a quick reference for locating and correcting engine trouble. The illustrations and procedures presented in each section apply to the engines listed on the cover. The flywheel end of the engine is the front end, so right and left sides are determined by viewing the engine from the front. The disassembly section contains major,. overhaul procedures for step by step .removal, disassembly, inspection, repair and assembly of the engine components. If a major repair or an overhaul is necessary, a competent mechanic should either do the job or supervise and check the work of the mechanic assigned to do the job to ensure that all dimensions, clearances and torque values are within the specified tolerances. The wiring diagram on the last page of the manual shows how the electrical components are inter- connected. A parts catalog (available at the dealer level) contains detailed exploded views of each assembly and the individual piece part numbers and their proper names for ordering replacement parts. Use only Genuine Onan replacement parts to ensure quality and the best possible repair and overhaul results. When ordering parts, always use the complete Model and Spec number as well as the Serial number shown on the nameplate. ENGINE MODEL REFERENCE c IUentlTy your moael DY reTerririy LO LII~ IVIWLKL aiiu nameplate. Always use this number and the engine serial number when making reference to your engine. SPEC (specification) NO. as shown on the unit ; How to interpret MODEL and SPEC NO. 1 2 3 4 1. Factory code for general identification purposes. 2. Specific Type: 3. Factory code for optional equipment supplied. 4. Specification (Spec Letter) advanceswith factory MS - ELECTRlC starting .with stub shaft. production modification. 2

Specifications All dimensions in U.S. customary units of measure (metric in parentheses) unless otherwise specified. UNIT OF SERIES SPECIFICATION MEASURE DJB DJBA DJE DJC Number of Cylinders 2 2 2 4 ASTM2-D ASTM2-D ASTM2-D ASTM2- D Diesel Fuel Bore in 3.25 3.25 3.5 3.25 (mm) (82.55) . (82.55) (88.90) (82.55) Stroke in 3.625 3.625 3.625 3.625 (mm) (92.08) (92.08) (92.08) (92.08) Displacement cuin . 60 60 70 120 (litre) (0.98) (0.98) (1-2) (1.97) Compression Ratio 19 to 1 19 to 1 19 to 1 19 to 1 Firing Order 1-2 1-2 1-2-4-3 Crankshaft Rotation Governor . Adjustable Mechanical Valve Clearance Spec A-C Begin Spec D Clockwise Clockwise Clockwise Clockwise (viewed from flywheel) Intake in 0.004 0.009 0.009 0.01 0 0.009 (mm) (0.10) (0.23) (0.23) (0.25) (0.23) Exhaust in 0.004 0.009 0.007 0.007 0.007 (mm) (0.10) (0.23) (0.18) (0.1 8) (0.1 8 Oil Filter Full Flow Full Flow Full Flow Full Flow Crankcase Capacity Qt 3.5 3.5 3.5 6.5 with filter change (I i tre) (3.3) (3.3) (3.3) (6.2) NOTE: DJB and DJBA engines differ only in crankshaft, injection pump, camshaft, and their associated piece parts. DJB is even-firing (pistons move up and down together); DJBA is odd-firing (one piston moves up as the other moves down. 3

Dimensions and Clearances All clearances given at room temperature of 70" F (21 O C) . All dimensions in inches (millimeters in parentheses) unless otherwise specified . CAMSHAFT Bearing Journal Diameter. Front ......................................... 2.2500-2.2505 (57.150-57.1 63) Bearing Journal Diameter. Rear .......................................... 1.1875-1.1880 (30.163-30.175) Bearing Clearance Limit (Original) .............................................. .0015.. 0030 (.038-.076) Bearing Clearance Limit (Replacement) .......................................... .0012-.0049 (.030-.123) End Play ............................................................................ .007-. 039 (0.2-1.0) Cam Tappet Diameter (Prior to Spec P) ...................................... .7475-. 7480 (18.987-18.999) Cam Tappet Hole Diameter (Prior to Spec P) .................................. .7507-. 7515 (19.068-19.088) Cam Tappet Diameter (Begin Spec P) ....................................... .8725.. 8730 (22.162-22.174) Cam Tappet Hole Diameter (Begin Spec P) .................................. .8755-. 8765 (22.238-22.263) Large Bore Diameter .................................................. 2.1871-2.1876 (55.5523-55.5650) Small Bore Diameter ...................................................... 1.043-1.045 (26.4922-26.543) Large Bearing Bore to Small Bearing Bore (Center-to-Center) .................................................. 5.998-6.002 (152.3492-152.4508) Connecting Rod End Play ............................................................ .002-. 016 (.05-.41) Bore Honed Diameter ...................................................... 3.2495-3.2505 (82.537-82.563) Bore Honed Diameter (DJE) ............................................... 3.4995-3.5005 (88.887-88.913) Maximum Allowable Taper ................................................................. 0.005 (0.127) Maximum Allowable Out-Of-Round .......................................................... 0.001 (0.025) Main Bearing Journal Diameter ............................................. 2.2437-2.2445 (56.99-57.01) Main Bearing Journal Diameter (DJC) .................................... 2.2427-2.2435 (56.965-56.985) Center Main Bearing Clearance (DJC) ........................................... .0024.. 0052 (.061-.132) Front and Rear Main Bearing Clearance (Original) (DJC) ......................... .0030.. 0043 (.076-.109) Front and Rear Main Bearing Clearance (Replacement) (DJC) ....................... .0024-.0062 (.06-.16) Main Bearing Clearance (Original) ............................................ .'. .. .002.. 0033 (.051-.084) Main Bearing Clearance (Replacement) ............................................ .0014.. 0052 (.04-.13) Connecting Rod Journal Diameter ........................................ 2.0597-2.0605 (52.316-52.337) Rod Bearing Clearance .......................................................... .001.. 0033 (.025-.084) End Play ......................................................................... .010-.015 (.254-.381) Clearance in Cylinder Measure 90" to pin. just below oil ring Bearing Journai uiaiiieiei. ueii~ei \UJ~) .................................. I LJUU- I LJUC [U 1 .a c r ~ - ~ 1 . acruJ CONNECTING RODS CYLINDER CRANKSHAFT . PISTONS AND RINGS (Prior to Spec P) ............................................................. .0050.. 0070 (.127-.178) (Begin Spec P) ............................................................... .0055-. 0075 (.140-.191) Ring Groove Width TOP ....................................................................... .0970-. 0980 (2.464-2.489) No.2 ...................................................................... -0965-.0975 (2.451-2.477) No . 3 ...................................................................... .0965.. 0975 (2.451-2.477) NO . 4 ...................................................................... .1880.. 1897 (4.775-4.818) Ring Gap ........................................................................... .010-. 020 (.25-51) Clearance in Piston ................................................................... Thumb Push Fit Connecting Rod Bushing Clearance ............................................. -0002-.0007 (-005-.018) PISTON PIN 4

STARTING MOTOR (Prestolite) Rotation ........................................................................... Counterclockwise Pinion Clearance to Pinion Stop (Solenoid Plunger Bottomed) . .... . . ...... ... . .... . -070--120 (1 -78-3.05) Armature End Play . ..... . .. ... . . .. . . . .... . .. . .. . . . . .. . .. . . . . ... . . ... . . ... . . ...... .005--030 (-030-.760) Stem Diameter (Stem is tapered) **Center .... ... . . . . .. ... . . . . .. . ..... . . . .. ... . . . .... . . . . ..... . . . . . . . . . . .. . .... -3401 -.3411 (8.639-8.664) **Face ....... .. ... .. .. . . . . . .. . .. . . . . . .. . . . .. . . . ... .. .. . . . . . . . . . . . . . . . ... .. .. . .3386--3396 (8.601-8.626) Valve Face ....................................................................................... 44' Guide Clearance .. . .. . .. .. .. ..... . ... . .. . .. . . . . . . . . . . . .. . . . .. . .. ... .. ... .. . .. .. . .0015-.003 (-038-.076) Stem Diameter . ... ... . . . . . .. ..... . ... . .. . . ... . .. ..... ........ ..... . .. . . .. . ... -3405--3415 (8.649-8.674) Guide Clearance . . . ..... . . .. .. . . .. .. . . . .. .... . ......... . . . ... ..... .. . . ... . ..... .0030-.0050 (.076-.127) Valve Face ....................................................................................... 45" Length .............................................................................. 1.7812(45.2424) Outside Diameter ....... . . .. . ... . .. ... . ...... . . . .... . . .... . .. ...... . .... .4690-.4695 (1 1.9126-1 1.9253) Inside Diameter (after reaming) Exhaust . . . . . .. . .. .. . . . ...... . ........ . .... . . . . ... . . . . .. . . . ...... .. .. . ..... .3445-.3455 (8.750-8.776) Intake ..................................................................... .3425-.3435 (8.700-8.725) Cylinder Block Bore Diameter.. ... ... . ... . .... . . . .... . . .. . . . . . . . .... . . ... . . . .467-.468 (11.8618-1 1.8872) Valve Seat Bore (Diameter) VALVE-INTAKE t VALVE-EXHAUST . VALVEGUIDE VALVE SEATS Intake .... . ... . . . . .. . ... .... . .. . .. . ..... . . . . . . ...... . . .. . . . .. . . . . . . ... . ... . 1.547-1 548 (39.29-39.32) Exhaust . ...... .. . .. ............ . .......... . . . ...... .. .. . . .. . . . ... . , .. . . . 1.361-1.362 (34.570-34.595) Depth (from Cylinder Head Face) .. . . . ... . .. . . . ... ... . . . . . . .. .... . .. . . . . . .. .. . .433-.439 (10.99-1 1.15) Exhaust .. . ... .. . . . .... . .... . .. . .... . ..... . .. .. . ... .... . . ........ . . .. 1.364-1.365 (34.6456-34.6710) Intake .... . . .. .. . . ... . .. .. .. . . . . .. :'. . ......... . . ... .. . .. . . .... . . . .. . .... ... 1 S50-1.551(39.37-39.39) Seatwidth ....................................................................... .047-.062 (1.19-1.57) Angle.. . . . ............... . ... .... . .. . ........ . . . .. .. . . ... . . ... . ..... . . . ...... . . .. . . . . . . . .... . .. 45" Available Insert Oversizes .. . ... . .. . .. . . . . . . .. ...... . ... . .... . . . . . . . . .. . ........ .. . .. . . . .... .002(.0508) .005 (.127) .010(.254) .025(.635) Load-Valve Closed . ... .. . .. . .. . ............... . .. . ... . . . . . . ............... . .. . . 45-49 Ib (200-218 N*) Load-Valve Open (Prior to Spec P) . .... . .. . ... . . .. . ... . . . . . . . . . ..... .. ... . .... . . 83-93 Ib '(369-414 N*) Load-Valve Open (Begin Spec P). ............ . . . .. .. .... .... . . . . ..... ..... . . . . .. 87-97 Ib (388-432 N*) Seat Outside Diameter VALVE SPRINGS 4 * N. Base unit, Newtons. Unit of force. ** Measure intake valve stem at points indicated. * Valve Stem Diameter (Intake) 2.96 in 1.18 in 5

Assembly Torques The assembly torques given here will assure proper tightness without danger of stripping threads. If a torque wrench is not available, be careful not to strip threads. Use reasonable force only and a wrench of normal length. Specially designed place bolts do not require a lock- washer or gasket. Check all studs, nuts and screws often and tighten as needed to keep them from work- ing loose. Special Tools TORQUE SPECIFICATIONS Ft.-Lb. Nom Center main bolt (4 cylinder). . .. . 97-102 (131-138) Connecting rod bolt., . .......... 27-29 Rocker-Box cover.. . . . . .. . .. . . .. 8-10 Cylinder head bolt . . . . . . . , .. .... 44-46 Flywheel mounting screw.. ..... . 65-70 Hub to flywheel screws (4 cylinder) .. .. . . , . . . .. . .. . . . . 17-21 Fuel pump mounting screws . . . . . 15-20 Gear case cover.. . . ... . .... . . . . . 15-20 Injection nozzle mounting screws .... . . . . . .... . ..... . . .. 20-21 Injection pump mounting screws ... . . . . ... . . . . . . ....... 15-16 Intake manifold . . . . . . . . . ... . .... 13-15 Oil base mounting screws . . . . . . . 45-50 Oil filter . . . . . . ... . . Hand tight plus 1/4 to 1/2 turn Oil pump mounting screws ...... 15-20 Rear bearing plate.. . . . . ... . . . . . . 40-45 Rocker arm nut . . . . . . ........... 4-IO** Rocker arm stud . . . . . . . .... ... . . 35-40 (37-39) (11-14) (60-62) (88-95) (23-28) (20-27) (20-27) (27-28) (20-22) (18-20) (61-68) (20-27) (54-61) (5-13) (47-54) 1 Q-I r;* 1.1 R-3l-l\ n-. -1- -_.-A -- -.-:.C-i A -. . & , . -. . . . -. -. - - . .. -. Glow Plug ... . . . .. . . . . . . ........ 10-15 (18-20) - Exhaust nuts must be tightened evenly. ** - This torque is due to friction between the threads only and locks the nuts in place. Use the rocker arm nut to adjust valve lash. h These tools are available from ONAN to aid service and Driver, Center Camshaft Bearing Driver, Combination Main and Cam ....... 420-0326 Reamer, Ridge. . .. . .. . . .. .. ..... . ....... 420-0260 Valve Guide Remover and Driver . . . ... . . . 420-0300 Diesel Nozzle Tester . . .... . . ............ 420-0184 Diesel Pintle Nozzle Cleaning Tool Set (Includes Injection Nozzle Centering repair work. (4 Cyl.) . ... . ..... . ...... . . . .. . . . . . . ... 420-0254 * Driver, Valve Seat . ....... . .. . . . . . . ... .. . 420-0270 . Oil Seal Guide and Driver.. .. . . ... ...... . 420-0456 Valve Seat Remover. . . ... . .. . ... . . . .. . .. 420-031 1 Replacement Blades for 420-0272 . .. .. . . . 420-0274 Crankshaft Gear Pulling Ring . ... .... . . . . 420-0409 Tool) .... .... ..... . ... . .. . . . .. ... . . . . 420-0208 6

Engine Troubleshooting

Onan Service Manual DJBA DJB DJC DJE Diesel Engine

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