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Table of Contents
- 1 Table of Contents
- 2 General Information
- 3 Specifications
- 4 Dimensions and Clearances
- 5 Assembly Torques and Special Tools
- 6 Engine Troubleshooting
- 7 Service and Maintenance
- 8 Exhaust System
- 9 Cooling System
- 10 Fuel System
- 11 Oil System
- 12 Governor System
- 13 Starting System
- 14 Engine Disassembly
- 15 Control System
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Table of Contents
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Summarization of Contents
Safety Precautions and Guidelines
Safety Codes and General Practices
Ensures compliance with codes and general safe operating procedures.
Protection Against Moving Parts
Advises on safety measures when working near engine moving parts.
Battery Safety Precautions
Outlines safety procedures for handling and servicing batteries.
Fuel System Safety Precautions
Details safety measures for fuel handling and system integrity.
Exhaust System Safety Precautions
Highlights hazards associated with exhaust gases and system checks.
Cooling System Safety Precautions
Warns about hot coolant and proper system handling.
Unit and Area Cleanliness
Emphasizes keeping the engine and surrounding area clean.
General Information and Model Reference
Introduction to the Manual
Provides an overview of the manual's content and purpose.
Engine Model Identification
Explains how to identify engine models using nameplate information.
Assembly Torques and Special Tools
Special Tools for Service
Lists specialized tools available from Onan for service and repair.
Assembly Torque Specifications
Provides specific torque values for engine assembly fasteners.
Service and Maintenance Procedures
Pre-Starting Checks
Essential checks before starting the engine.
Crankcase Oil Recommendations
Guidance on selecting the correct SAE viscosity grade for engine oil.
Recommended Fuel
Details on diesel fuel grades and usage based on conditions.
Onan Diesel Starting Guide
Starting and Stopping Procedures
Step-by-step instructions for starting and stopping the engine.
Engine Operation and Troubleshooting
Engine Failure to Start Troubleshooting
Guides to diagnose and resolve starting issues.
Automatic Operation and Load Application
Information on automatic controls and applying load to the engine.
Break-in Procedure and Inspection
Initial engine break-in process and installation inspection.
Environmental and Operational Factors
Ventilation and Low Temperatures
Importance of ventilation and precautions for cold weather operation.
Exhaust, Batteries, and Dust/Dirt
Maintenance tips for exhaust, battery, and dust/dirt control.
High Altitude Effects
Describes power reduction at higher altitudes.
Maintenance Procedures
Oil Filter Change
Step-by-step instructions for replacing the oil filter.
Oil Drain Extension Installation
Guidance on installing a convenient oil drain extension.
Engine Storage and Return to Service
Out-of-Service Protection
Procedures for protecting the engine during extended storage.
Returning Unit to Service
Steps to safely prepare a stored engine for operation.
Cooling System
Purpose and Corrosion Prevention
Explains cooling system function and preventing corrosion.
High Temperature Cut-Off Switch
Details the function and operation of the high temperature switch.
Cooling System Maintenance and Cleaning
Procedures for cleaning, flushing, and maintaining the cooling system.
Cooling System Components
Engine Water Jacket and Cylinder Head
Describes potential leaks in the water jacket and cylinder head.
Thermostat Function and Testing
Explains thermostat operation, testing, and replacement.
Draining Cooling System
Procedure for draining the cooling system for maintenance.
Pressure Cap Functionality
Details the function and maintenance of the cooling system pressure cap.
Cooling System Operation
Radiator Cooled System Description
Explains the operation of a radiator-cooled engine system.
Water Pump Description and Service
Details the water pump's function, removal, and installation.
Cooling System Types
City Water Cooled System
Describes the operation of a city water cooled engine system.
Heat Exchanger Cooling (Optional)
Details the optional heat exchanger cooling system.
Fuel System Overview
Diesel Fuel Properties
Covers diesel fuel characteristics and pour point importance.
Fuel Cleanliness and Water Prevention
Emphasizes keeping diesel fuel clean and free from water.
Fuel System Components
Fuel System Configuration
Describes fuel system components including tank and lines.
Fuel Filter System
Details the filter system and water in fuel filter maintenance.
Fuel System Details
Fuel Tank and Line Installation
Guidance on installing fuel tanks and lines, avoiding gravity feed.
Fuel Transfer Pump Operation Details
Further details on the operation of the fuel transfer pump.
Injection Nozzle Service
Fuel Pump Removal and Disassembly
Procedure for removing and disassembling the fuel pump.
Nozzle Installation and Operation
Covers nozzle installation, operating principle, and adjustment.
Nozzle Checks and Adjustments
Nozzle Spray Pattern Check
How to check and identify nozzle spray patterns.
Nozzle Adjustment and Disassembly
Procedures for adjusting nozzle pressure and disassembly.
Nozzle Maintenance Procedures
Injection Nozzle Tester Use
Instructions for using an injection nozzle tester.
Nozzle Repair and Installation
Guidance on nozzle repair, replacement, and installation.
Preheating Circuit and Injection Pumps
Preheating Circuit Description
Details the 12-volt battery circuit for preheating.
Injection Pump Repair
Information on required tools and procedures for injection pump repair.
PSU Injection Pump
Description of the PSU injection pump used on 4-cylinder engines.
PSU Injection Pump Operation
PSU Pump Mechanism
Explains how the PSU pump is driven and operates.
PSU Pump Cutaway View
A detailed cutaway view of the PSU pump's internal components.
Injection Pump Timing Components
Metering Sleeve Operation
Describes how the metering sleeve is positioned by the governor.
Timing Button Code and Thickness
Information on timing button codes and selecting the correct thickness.
Injection Pump Timing Methods
Method 1: Timing by Calculation
Procedure for timing the injection pump using calculation.
Port Closing Formula
Formula to determine the correct timing button thickness.
Pump Operation and Timing
Operating Transfer Pump Manually
Steps for manually operating the fuel transfer pump.
Identifying Timing Marks
Guidance on locating and using timing marks on the flywheel.
Fuel System Delivery and Bleeding
Delivery Valve Function
Explains the role of the delivery valve in maintaining line pressure.
Bleeding Fuel System
Procedure for removing air from the fuel system.
Oil System Service
Oil Pump Service
Covers oil pump removal, repair, and installation.
Oil Lines, Filter, and Breather
Oil Lines and Restrictions
Details oil line routing, restrictions, and cleaning.
Oil Filter Replacement
Instructions for replacing the full-flow oil filter.
Crankcase Breather Service
Procedure for cleaning the crankcase breather system.
Governor System
Governor Description and Maintenance
Explains governor function, linkage, and maintenance.
Governor Testing and Repair
Methods for testing governor spring rates and repair.
Starting System
Starting System Maintenance and Testing
Covers maintenance of the starting circuit and performance testing.
Starter Motor Repair Procedures
Starter Motor Component Repair
Details repair for field coils, bearings, and brushes.
Over-running Clutch and Solenoid
Service for the over-running clutch and shifting solenoid.
Prestolite Starter Service
Prestolite Starter Removal and Disassembly
Step-by-step guide for removing and disassembling the starter.
Prestolite Starter Assembly
Instructions for assembling the Prestolite starter motor.
Mitsubishi Starter Service
Mitsubishi Starter Removal and Installation
Procedures for removing and installing the Mitsubishi starter.
Mitsubishi Starter Disassembly
Detailed steps for disassembling the Mitsubishi starter motor.
Mitsubishi Starter Assembly and Adjustments
Mitsubishi Starter Assembly
Instructions for assembling the Mitsubishi starter motor.
Pinion Shaft End Play Adjustment
How to adjust the end play of the pinion shaft.
Starter Installation Details
Pinion Gear Installation
Procedure for installing the pinion gear assembly.
Lever Assembly Installation
Correct method for installing the lever assembly, spring, and packing.
Pinion Gap Adjustment
Procedure for adjusting the pinion gap on the starter.
Belt Driven Charging Alternator
Brush Assembly Removal
Steps for removing the brush assembly from the alternator.
Brush Assembly Tests
Tests to check the continuity and shorts in the brush assembly.
Engine Disassembly and Reassembly
Engine Rebuilding Process
Overview of the engine rebuilding process and component handling.
Engine Disassembly Procedure
A suggested step-by-step procedure for engine disassembly.
Engine Assembly Guidelines
Important tips and considerations for engine assembly.
Valve Maintenance and Adjustments
Valve Clearance Maintenance
Regular checks and cleaning of valve clearances.
Valve Clearance Adjustment Procedure
Step-by-step guide for adjusting valve clearances.
Cylinder Head and Valve Service
Cylinder Compression Testing
Procedure for testing cylinder compression.
Cylinder Head Disassembly
Detailed steps for disassembling cylinder heads.
Cylinder Head Repair
Instructions for cleaning and repairing cylinder heads.
Valve Service Procedures
Covers valve refinishing, guide checks, and seat work.
Flywheel and Gear Cover Service
Flywheel Removal and Replacement
Instructions for removing and replacing the flywheel.
Gear Cover and Governor Shaft Removal
Procedure for removing the gear cover and governor shaft.
Gear Cover Oil Seal and Governor Cup Service
Gear Cover Oil Seal Replacement
Guidance on replacing the gear cover oil seal.
Gear Cover Assembly
Steps for assembling the gear cover.
Governor Cup Removal
Procedure for removing the governor cup from the camshaft.
Pistons, Rings, and Connecting Rods
Removal and Disassembly Steps
General steps for removing pistons, rings, and connecting rods.
Cylinder Inspection
Checking cylinder walls for wear, taper, and out-of-round.
Piston and Piston Pin Inspection
Inspection of pistons, ring grooves, and piston pin fit.
Ring Fitting and Connecting Rods
Details on fitting rings, checking gaps, and rod/bearing inspection.
Connecting Rod Assembly and Camshaft Service
Connecting Rod Assembly and Installation
Instructions for assembling connecting rods to pistons and crankshaft.
Camshaft Removal and Repair
Procedure for removing, repairing, and replacing the camshaft.
Crankshaft Service
Crankshaft Removal
Steps for removing the crankshaft from the engine.
Crankshaft Inspection
Checking crankshaft journals for wear and damage.
Crankshaft Grinding
Procedures for grinding and shot-peening crankshaft journals.
Rear Oil Seal and Installation
Instructions for replacing the rear crankshaft oil seal.
Crankcase and Break-in Period
Crankcase Replacement Considerations
Information on replacing the crankcase and associated parts.
Engine Break-in Period
Guidelines for the initial engine break-in process.
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