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New 4 cylinder Onan diesel generator


Hi. Very new to the forum and to generators, I found this site thru the MTF tractor forum.Anyway...

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  #1  
Old 08-18-2011, 09:04 PM
EnginePat EnginePat is offline
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Talking New 4 cylinder Onan diesel generator

Hi. Very new to the forum and to generators, I found this site thru the MTF tractor forum.Anyway here goes and thanks in advance.

I was given a 4 cylinder air cooled diesel Onan generator blue in color. It will not turn over although the starter engages the flywheel, I think the engine is seized from sitting,it sat for 4 years.The eng/gen is in a housing but it is missing a door in the side. It looks like it was hard wired in the last place it was hooked to. It has a duplex 110v outlet mounted on the inside. There is a starter toggle switch and glow plug toggle switch mounted inside and under a door on the end outside housing under a small door
The generator has no tags on it so I can't ID it,I was going to post up some pics but the battery was dead in the camera phone. So if I pull the heads off are parts for this engine availible once I am able to ID it?

pat
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Old 08-18-2011, 09:11 PM
Wayne 440 Wayne 440 is offline
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Default Re: New 4 cylinder Onan diesel generator

There is a good chance that your set is a DJC. Most parts are available, but not always new ones, Onan made many of those. Some parts are expensive enough to provoke profanity, new or used.
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Old 08-18-2011, 09:17 PM
EnginePat EnginePat is offline
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Default Re: New 4 cylinder Onan diesel generator

Thanks for the quick reply, Is there somewhere else on the engine I can find a ID?
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Old 08-18-2011, 09:21 PM
Max Thompson Max Thompson is offline
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Default Re: New 4 cylinder Onan diesel generator

Charge up the camera battery & post some pictures, otherwise all you will receive will be guesses about what you have. There should be a number “stamped” in the side of the engine block, find that & the smart guys can work their magic.
I know nothing about diesels, but my first thought is to get some penetrating oil into each cylinder. There are many flavors, mine is PB Blaster though anything is better than nothing. I assume you will have to pull the injectors to do this, I am sure one of the diesel guys will be along shortly to help out. Let it sit & soak overnight, then try a breaker bar on the flywheel bolt. Gently rock back & forth to start. When we know what you have the suggestions will be more precise.
When you get it loose, give it a fresh oil change before starting it.
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Old 08-18-2011, 09:26 PM
EnginePat EnginePat is offline
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Default Re: New 4 cylinder Onan diesel generator

Yes tomorrow I will post up some. Thanks
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Old 08-18-2011, 09:27 PM
Wayne 440 Wayne 440 is offline
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Default Re: New 4 cylinder Onan diesel generator

http://www.smokstak.com/forum/showpo...21&postcount=1

Look at the pix in the above post. That is a DJC.

There are numbers on the engine block someplace that may allow a more specific ID. Perhaps one of the more experienced members will be able to tell you where to look.
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Old 08-18-2011, 09:36 PM
EnginePat EnginePat is offline
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Default Re: New 4 cylinder Onan diesel generator

That it! But it has a housing around it.
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Old 08-18-2011, 10:07 PM
K D Redd K D Redd is offline
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Default Re: New 4 cylinder Onan diesel generator

Quote:
Originally Posted by enginepat View Post
Thanks for the quick reply, Is there somewhere else on the engine I can find a ID?
The engine was made by ONAN.

Kent
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Old 08-18-2011, 10:21 PM
EnginePat EnginePat is offline
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Default Re: New 4 cylinder Onan diesel generator

Yea I saw that on the engine and some other numbers. tomorrrow I will post them up.
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Old 08-18-2011, 11:11 PM
Isaac-1 Isaac-1 is offline
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Default Re: New 4 cylinder Onan diesel generator

As to the topic of getting a seized engine to free up, I bought a John Deere 4 cylinder diesel powered generator a few years ago off GL , the muffler had been removed and exhaust manifold taped over, however while it was stored outside the tape rotted away. When I picked it up I found about a gallon of water in the bottom of the oil pan, and the engine seized, I drained the water, added a 50/50 mix of about a gallon of ATF and Marvel mystery oil, to the exhaust manifold so it could drain down into the open cylinders, let it sit for several days. It then turned over and I was able to get it started, it has ran fine ever since with no other work needed (probably has 100+ hours of run time since then).

Ike
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Old 08-19-2011, 12:45 AM
bbuchorn bbuchorn is offline
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Default Re: New 4 cylinder Onan diesel generator

The generator you have sounds like it has a "J" series diesel engine. these were used on a lot of ONANs . the numbers these guys need is "Stamped" NOT cast into the side of the engine block on a smooth machined surface on the right front side just above the bottom block flange, probably behind the fuel filter housings and below the oil filler neck. Try this manual and see if the engine is close to yours. - http://www.cumminsonan.com/www/pdf/manuals/967-0751.pdf
Personnally I wouldn't pull the heads unless I had no choice. Pull the glow plugs or the injectors and soak the tops of the pistons in your favorite penetrating oil and try to free it up by hand first. Save any parts during your careful dissasembly as you will probably have to reuse them or make new. Gaskets an stuff are hard to find for these specially if you don't know the proper part number. If you pull the injectors, save the copper ring gaskets, anneal them before reuse by heating to red hot and alowing them to cool slow. Above all POST SOME GOOD PICS!! The guys here love good pictures and the challenge of helping someone like you. Good luck, We'll be looking for more.
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Old 08-19-2011, 09:08 AM
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Default Re: New 4 cylinder Onan diesel generator

I like pictures really like the ones that fold out.

What you most likely have is a housed DJC. Very common unit.
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Old 08-19-2011, 04:32 PM
bbuchorn bbuchorn is offline
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Default Re: New 4 cylinder Onan diesel generator

Yeah staples get in the way sometimes though.
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Old 08-19-2011, 06:47 PM
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Default New 4 cylinder Onan diesel generator

Ok pictures
Attached Thumbnails
onan 012.jpg   onan 013.jpg   onan 008.jpg   onan 005.jpg   onan 006.jpg  

onan 014.jpg   onan 010.jpg   onan 015.jpg  
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Old 08-19-2011, 06:55 PM
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Default Re: New 4 cylinder Onan diesel generator

So in one of the pictures the place wher the ID tags would have been are gone.
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Old 08-19-2011, 07:22 PM
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Default Re: New 4 cylinder Onan diesel generator

DJC and the tag would have been on the front shroud.

I hate stables.
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Old 08-19-2011, 11:22 PM
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Default Re: New 4 cylinder Onan diesel generator

Ok tomorrow I will pull off all the housing sheet metal and then the cooling fan and bolt a bar to the flywheel. I dumped diesel and atf in the exhaust tonight. I wll try and rock the engine later tomorrow.
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Old 08-20-2011, 02:57 AM
Old Style Old Style is offline
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Default Re: New 4 cylinder Onan diesel generator

Don't expect it to come free immediately; it didn't freeze/rust up that way. Take your time and give it a bump in one direction then the other. A little at a time over a period of days will lessen the damage to the rings.
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Old 08-20-2011, 09:30 AM
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Default Re: New 4 cylinder Onan diesel generator

Thanks for the advice,I will pull the injectors also and pour some deep creep down thru the holes also. I did find that the muffler flex pipe was broken this morning,made it easy to remove the top of the housing. Hopefully critters didn't find there way into the engine.
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Old 08-20-2011, 10:53 AM
Max Thompson Max Thompson is offline
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Default Re: New 4 cylinder Onan diesel generator

With any luck you will get the engine loose with little effort. But, if is it is really stuck.
After you get the sheet metal off & expose the flywheel, you should find 4 - 7/16” bolt holes in the front of the fly wheel around the center bolt. Cut yourself a piece of flat 1 ½” x ¼” (or what ever you have handy) steel long enough to span 2 opposing bolt holes, drill holes in your flat to match the holes in the fly wheel. Weld an 8” length of 1 ¼” (or what ever you have) square stock to the face of the flat plate. Remove the center bolt in the fly wheel & attach this to the front of the fly wheel with a couple of 7/16” bolts. This gives you a place to get a BIG wrench on with which to rock the crank shaft back & forth, while staying clear the cooling fins around the outer edge.
Be very careful with the fly wheel, it is cast iron & the “fins” around the outer edge are VERY easy to break off. The fly wheel is a “tapered” fit to the crank with a half moon key in it, so do not over tighten it trying to get the engine loose, you can break the fly wheel or shear the bolt.
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