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General| Rated Speed | 1800 RPM |
|---|---|
| Governor Type | Mechanical |
| Engine Type | Diesel |
| Aspiration | Naturally aspirated |
| Cooling System | Liquid Cooled |
| Rotation | Counterclockwise |
Covers fire extinguishers, fastener security, and safe adjustments near moving parts.
Advises on appropriate clothing and keeping hands clear of moving engine components.
Details battery disconnection, avoiding smoking, and correct polarity.
Focuses on fire hazards, fuel line integrity, and leak prevention.
Discusses toxicity, confinement, carbon monoxide hazards, and leaks.
Warns about hot coolant, pressure caps, and potential burns.
Emphasizes keeping the unit clean to prevent fire hazards.
Describes the manual's purpose, scope, and how to use its sections.
Explains how to identify engine models and interpret specification numbers.
Lists key engine specifications like bore, stroke, displacement, and compression ratio.
Details battery group size, voltage, and cranking performance at various temperatures.
Provides critical dimensions for camshaft journals and connecting rods.
Lists dimensions for crankshaft journals and cylinder bore.
Specifies clearances for pistons, rings, pins, and connecting rod bushings.
Details rotation, pinion clearance, and armature end play for the starter.
Provides stem diameters, guide clearances, and face angles for intake and exhaust valves.
Lists specifications for valve seats and valve spring loads.
Lists critical torque values for engine assembly fasteners.
Lists specialized tools available from Onan for repair and service.
Identifies causes for starting system failures.
Lists potential causes for fuel system malfunctions.
Identifies causes for oil pressure and lubrication issues.
Lists causes for governor control loss or hunting.
Identifies causes for overheating or coolant issues.
Lists causes for internal engine problems like poor compression.
Outlines essential checks before operating the engine.
Specifies oil viscosity grades based on ambient temperature.
Details fuel grades and conditions for optimal engine performance.
Emphasizes the importance of keeping the fuel system clean and free from water.
Step-by-step guide to remove air from the diesel fuel system.
Details preheating duration and engine starting sequences.
Explains the correct method for shutting down the engine.
Provides guidance for diagnosing and resolving engine start failures.
Recommends procedures for connecting loads to the engine.
Outlines the recommended steps for the initial engine run-in period.
Advises on checking alignment and overall installation integrity.
Stresses the need for adequate ventilation for cooling and combustion.
Provides guidance for cold weather starting and operation.
Covers exhaust pipe requirements, routing, and safety.
Details regular checks for battery condition and connections.
Advises on keeping the engine and air cleaner free of dust and dirt.
Explains power reduction at higher altitudes and recommendations.
Describes the correct method for changing the oil filter.
Explains how to install an extension for easier oil draining.
Details cleaning procedures for the crankcase breather components.
Brief mention of inspecting the ball joint.
Details steps for protecting the engine during extended storage.
Outlines procedures for bringing a stored engine back into operation.
Covers exhaust function, back pressure limits, and noise muffling.
Explains what different exhaust smoke colors indicate.
Provides guidelines for proper exhaust system installation.
Addresses specific requirements for indoor exhaust setups.
Details pipe length, bend equivalencies, and sizing for back pressure.
Explains how to install a trap for pitched exhaust lines.
Highlights the dangers of carbon monoxide from exhaust gases.
Explains the function of the cooling system in engine operation.
Discusses coolant mixtures and corrosion prevention.
Describes the function of the switch in preventing overheating.
Outlines regular maintenance tasks for the cooling system.
Details procedures for cleaning rust and scale from the system.
Discusses internal and external coolant leaks in the engine block.
Explains how to test thermostat operation and when to replace it.
Details procedures for draining all coolant from the system.
Describes the role of the pressure cap in raising coolant boiling point.
Explains the water flow and component interaction in a radiator system.
Describes the water pump's role and checks for wear.
Details the steps required to remove and install the water pump.
Explains how systems using city water for cooling function.
Describes the optional heat exchanger system with two water circuits.
Details maintenance for the closed water loop, including flushing and anti-freeze.
Outlines periodic checks for air leaks, wear, and restrictions in the raw water system.
Outlines steps for pump repair and replacement of worn components.
Describes how to assemble the pump and adjust impeller clearance.
Describes diesel fuel properties, ignition, and required factors.
Explains the importance of pour point for cold weather fuel flow.
Stresses keeping fuel clean and free from water for system longevity.
Lists the main parts of the fuel system including pump, filters, and injectors.
Explains the function of the sediment bowl and primary/secondary filters.
Covers replacement intervals for primary and secondary fuel filters.
Provides guidelines for installing fuel tanks and lines.
Describes the transfer pump's function and procedures for repair.
Explains how injection nozzles inject fuel into the combustion chamber.
Describes how to check the nozzle spray pattern for defects.
Details the critical cleaning process for injection nozzles.
Explains how to use a nozzle tester for checking and adjustment.
Outlines steps for safely disassembling injection nozzles.
Steps for installing injection nozzles into the cylinder head.
Explains the role of the fuel shutoff solenoid in engine control.
Details how to adjust the fuel solenoid plunger for proper operation.
Explains the 12-volt circuit for manifold heaters and glow plugs.
Describes the function and testing of preheating components.
Introduces the PSU injection pump used on 4-cylinder diesel engines.
Explains how the PSU pump is driven and operates.
Details internal pump components and fuel flow paths.
Explains how the metering sleeve controls fuel delivery based on lever position.
Details the timing button's role and how to select the correct thickness.
Outlines the procedure for calculating timing button thickness using old pump data.
Provides the formula for determining the correct timing button thickness.
Describes the method for timing the pump using fuel flow observation.
Shows the connection of fuel lines from the pump to the injectors.
Describes how to manually operate the fuel transfer pump for priming.
Explains how to locate and use flywheel timing marks.
Details the steps for installing the injection pump onto the engine.
Covers pump mounting, gear alignment, and spring pressure checks.
Explains the procedure to lock the drive gear for pump installation.
Explains the role of the delivery valve in maintaining line pressure.
Describes the procedure to bleed air from the fuel system after filter changes.
Explains the components of the engine's pressure lubrication system.
Details the steps for removing and installing the oil pump.
Describes the bypass valve's role in controlling oil pressure.
Details procedures for cleaning lubrication passages and orifices.
Discusses oil line routing and the function of restriction orifices.
Explains the crankcase breather system and its cleaning.
Explains the governor's role in maintaining constant engine speed.
Describes governor components and basic adjustments.
Covers linkage inspection and testing governor spring rates.
How to adjust engine governed speed using the spring nut.
How to adjust governor sensitivity (speed droop).
Describes the starter motor, solenoid, and starting circuit.
Covers checks for wiring, connections, and brushes.
Outlines tests for cranking issues like low speed or high current draw.
Describes how to test the starting motor's stall torque.
Covers battery capacity, charging system, and voltage drop tests.
Details repair procedures for armature, field coils, bearings, and brushes.
Covers inspection and testing of the over-running clutch and solenoid.
Provides steps for removing and disassembling the Prestolite starter.
Details the procedure for reassembling the Prestolite starter motor.
Steps for removing and installing the Mitsubishi starter motor.
Provides procedures for disassembling the Mitsubishi starter.
Details the correct procedure for reassembling the Mitsubishi starter.
How to adjust the pinion shaft end play using washers.
Describes the process of installing the starter pinion gear.
Details the correct method for installing the starter lever assembly.
Explains how to adjust the pinion gap using solenoid mounting washers.
Steps for removing the alternator brushes and related parts.
Tests for checking brush continuity and shorts.
General approach to engine disassembly for rebuilding.
A suggested order for disassembling engine components.
Key points and special tools to keep in mind during engine assembly.
Important aspects to consider during engine assembly.
Step-by-step guide for adjusting valve clearances when cold.
Continued steps for adjusting valve clearance for all cylinders.
Details on how to perform a cylinder compression test.
Steps for removing cylinder heads from the engine block.
Machining procedures for valve seats and oversize inserts.
Procedures for installing and facing new valve seats.
How to check valve springs for tension and condition.
Steps for installing the cylinder head, valves, and related components.
How to remove and install the flywheel and ring gear.
Steps for removing the gear cover assembly.
How to remove the governor shaft from the gear cover.
How to replace the oil seal in the gear cover.
Steps for assembling the gear cover with governor components.
How to remove the governor cup and flyballs.
How to inspect pistons and rings for wear and damage.
Checking cylinder walls for wear, out-of-round, and reboring options.
How to inspect and clean pistons, including ring grooves.
Procedures for installing piston pins into pistons.
How to check connecting rods and bushings for defects and clearance.
How to inspect connecting rod bearings for wear and damage.
Steps for assembling and installing connecting rods onto the crankshaft.
Steps for removing the camshaft from the engine block.
How to repair or replace a worn or scored camshaft.
How to remove the camshaft gear from the shaft.
Procedures for replacing camshaft bearings.
Steps for removing the crankshaft from the crankcase.
How to inspect crankshaft journals for wear and damage.
Procedures for grinding and shot-peening crankshaft components.
How to replace main bearings and thrust washers.
How to replace the rear oil seal on the bearing plate.
Steps for installing the crankshaft into the engine block.
Specifics on installing main bearings and housing alignment.
Considerations for replacing the crankcase and associated parts.
Recommendations for the initial engine run-in after major work.
Explains the purpose of engine operating controls.
Advises on periodic checks of control system connections.
Shows the schematic for a typical standard engine control system.
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