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Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160


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  #1  
Old 12-23-2012, 02:56:00 PM
edd b edd b is offline
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Default Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

I have an Onan Genset with a 5.95L Ford Dorset diesel model #2713E with minimec injector pump. When engine cranks, it tries to run at extremely high RPM. Could this be an adjustment problem or an internal pump problem? Any help would be appreciated.

Thanks!
Edd B
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  #2  
Old 12-23-2012, 04:06:18 PM
Jim Rankin Jim Rankin is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

Rack will stick in the injection pump. Make sure there isn't any external throttle adjustment that has it rev-ed up though.

The one I have is on a pump, so may not have strictly the same governor and injection pump setup as the generator spec engine. The following comments refer to a Simms MiniMec in-line pump.

Anyway, check and maybe change the oil in the injection pump housing. There is a hex head drain plug on the bottom, another similar check plug on the side and a larger fill plug on top with a screwdriver slot in it. Usually use a good grade of motor oil in it, should hold less than a quart.

Take the cover off the side by removing two bolts and then move the rack back and forth gently, It is a horizontal bar that engages a gear sector on the bottom of all 6 injection pump plungers. It should move easily back and forth. If it doesn't move, one or more of the injection pump plungers may be stuck up in the pump barrels and have the rack locked in place. Use penetrating oil and spray the plungers and the lifter mecahnisms with the return springs on them. Carefully work the plungers up and let the spring pull them back down until they all work perfectly freely.


Also check for broken coils on the lifter springs, have had several break and only cause a misfiring cylinder, but also had one lock the rack in the shutoff postion (better....no chance of a runaway like you have)

I'm guessing yours is shutting down with an electric fuel valve in the line and not by the injection pump lever that pulls the rack to shutoff position.

If you need, I can probably take some pictures, or if you'll take some of your injection pump assembly, and post on here, I can comment.
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Old 12-24-2012, 02:36:51 PM
edd b edd b is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

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ID:	152997I'm not sure if you got my previous reply or not. I'm having trouble figuring out how to send pictures. I'm trying this one more time.

You were right on Jim. The pump was pretty cruddy. The rail is frozen. Will move very little. I am soaking it now and have gotten it to move a little bit, but I can't see any pistons moving up and down. Can I take the upper plate off and see the pistons better? If these pictures give you any insight, please let me know. Thank you so much for your help.

Thanks
Edd B
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Old 12-24-2012, 04:30:20 PM
Zeromedic Zeromedic is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

Hi Edd,

I know almost zero about diesels, but I do have a pdf copy of the factory service
manual covering your Ford Dorset 2713. The manual is so big (35 MegaBytes) that
I had to split into 2 parts so I could email it to another member here.

Let me know if you would like a copy, either by posting your email address here, or
click my username and send me an email or PM with your address. Note, it is not
possible to send large attachments directly thru smokstak email server, need a real
address to send to.

Here is a snippet from the service manual, that shows some detail of your pump.

hth, Steve

ps. edd and mike, you both should have mail.
Attached Files
File Type: pdf pump.pdf (114.6 KB, 48 views)

Last edited by Zeromedic; 12-25-2012 at 03:22:49 PM. Reason: manuals sent
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Old 12-24-2012, 05:13:00 PM
Jim Rankin Jim Rankin is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

The cover you have removed for the pictures is the only convenient access to the pump. I would avoid taking the top off the injection pump unless you really have to. It's not hard to take off if you can't get things free any other way. I had to remove mine to replace some of the springs you see through the cover opening after the 3rd time I had some break. Each time I sent the pump to the shop it took a few days when I needed to be running 24 hours a day watering crops, so the last time I did it myself.

If you have someone crank the engine over, you should see that the springs visible behind the rack are alternately compressed (injection stroke around TDC for each piston) and then expand again as the cam lobes rotate underneath. If any do not expand like the rest of them, a plunger is stuck in the pump and should be sprayed with penetrating oil and worked up and down with a screwdriver etc until it returns to the base circle of the camshaft on it's own. If you have a pump sticking or stuck, you will have a misfire, but on a 6 cylinder, you may not take much notice of it unless you're used to listening to the engine. Be gentle with the rack, I expect it's possible to change the fuel delivery for each pump if you get brutal with it and there's a stuck pump plunger that has it locked up. I have just pried the rack back and forth until it would move on it's own on a large CAT engine, and it worked out fine, but the MiniMec rack doesn't seem to be too robust to me.

It may be that the only thing stuck in your case is the rack and governor. The rack is normally free to move back and forth quite easily with just a finger or screwdriver to slide it. As the engine speeds up, the governor flyweights come into play and oppose the action of the governor spring which is trying to open the rack to full fuel whenever the engine isn't turning as fast as the setpoint rpm (1800 in your case).

I see that the shutdown mechanism on this one is a solenoid to pull the rack to fuel "off" position. There should be some sort of throttle setting mechanism on the engine side of the pump, probably good to make sure that someone hasn't tampered with it, but with the appearance of the housing inside the cover, I believe your troubles have mostly to do with corrosion.
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Old 12-24-2012, 09:00:45 PM
Mike Dennis Mike Dennis is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

Zeromedic, you have incoming!! A DEG is my whole house back-up and recently installed a DEF for a friend. The only manual I do not have is one for the engine so would LOVE to have it / them!!!!

Thank you for offering!
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Old 12-25-2012, 10:40:30 AM
edd b edd b is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

Zeromedic - you have incoming from me as well. I would love to have a copy of the manual.

Thanks
Edd B
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Old 12-25-2012, 09:17:02 PM
Mike Dennis Mike Dennis is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

Zeromedic, the manuals arrived fine. Thank you VERY much!!!!
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Old 01-31-2015, 06:20:18 PM
machfab machfab is offline
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Default Re: Onan DEF 45 Generator Model #ODEF15R9316J, Serial #J760178160

Zeromedic, could you send copy of manual to me. Thanks
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