Onan MDJF Owner's Manual

OPERATORS

AND

FOR

nan

O

ANUAL

t

ELECTRIC

GENERATING

MDJF

SEkiES

SETS

968-0345

6Abt3

TABLE
TITLE PAGE
General Information

Specifications
Dimensions
Assembly Torques
Installation
Operation
Adjustments
General Maintenance
Routine Check Chart

Maintenance Schedule
Troubleshooting Guide

Parts Catalog

and

8

. 17

21

3

4

Clearances

and

24
26

29

OF

CONTENTS

5

Special Tools

. . 27

28

7

PERFORMANCE

CERTIFIED

We
this Onan electric plant
voltage and frequency regulation promised by its
and published specifications. This plant has
hours
in
testing laboratory.

certify

of running-in and testing

accordance

ONAN

that when properly installed and

with

1400 73RD AVENUE

will

deliver the

procedures

N.E. •

full

power and the

under

certified

MINNEAPOLIS, MINNESOTA 55432

* OIVISIOH Of ONAN CORPOI'llON

undergone

realistic load conditions,

by an independent

operated

nameplate

several

IMPORTANT!

RETURN

WARRANTY

CARD

ATTACHED

TO

UNIT.

INTRODUCTION

THIS OPERATOR'S
TO THE INSTALLATION, OPERATION, AND MAINTENANCE OF YOUR
ONAN
MANUAL.

WE SUGGEST THAT THIS
ACCOMPANIES
TO
ADDITIONAL COPIES ARE AVAILABLE FOR A
FROM YOUR

WHEN
MODEL, SPECIFICATION
ON THE NAMEPLATE OF YOUR
ENSURE

FOR

DISTRIBUTOR.

UNIT.

WHEN

ORDERING PARTS REMEMBER TO INCLUDE THE

MAJOR REPAIR

A PARTS CATALOG IS ALSO INCLUDED IN THIS

MAKING

ONAN

THE CORRECT PART IS SHIPPED TO YOU.

MANUAL

EVERY

ONAN

EQUIPMENT ADJUSTMENTS OR ORDERING PARTS.

DISTRIBUTOR.

SERVICE,

CONTAINS

MANUAL

UNIT

LETTER,

ONAN

CONTACT YOUR

INFORMATION

AND THE

BE RETAINED AND

AND SERIAL NUMBER LOCATED

UNIT.

WIRING

NOMINAL

THIS IS ESSENTIAL TO

ONAN

PERTAINING

DIAGRAM

REFERRED

CHARGE

AUTHORIZED

WHICH

ONAN

GENERAL

When

the insttuctions in this manual refer to a specific

INFORMATION

model of generating set, identify the model by referring
to the

the

MODEL

Onan

AND

nameplate.

SPECIFICATION

Electrical

characteristics are shown

NO. as shown on

on the lower portion of the set nameplate.

How

to

Interpret

MODEL

15

OMDJ F - 4R /

and

96

SPEC

D

NO.

1. Factory

2.

Specific

code

Type:
E - ELECTRIC.
R - REMOTE.

1

for general identification.

Electric

Electric

starting. For permanent installa-

3

4

starting at the set only.

tion, can be connected to optional accessory equipment
for remote or automatic control of starting and stopping.

3.

Factory

code

for optional equipment.

4. Specification (Spec) letter (advances when factory
makes production modifications).

CAUTION

WARNING

i^J&/e personal injury.

H^HHMBB

'Onan uses this symbol throughout

to warn

s sym

|^"

ol

possible equipment damage.

^ 's used

to

warn

ol any

the

possi-

text

MANUFACTURER'S

Onan warrants. In ihe
is

frrr

frnm

siollcil.

serviced and operated under normal conditions according to

inplrnrlinno.
Onan

will,

pan

which

hern

defeciive in material and workmanship: provided lhat such part
he returned to
ironsporluiion
if

first

placed in
free of charpe,
during

ihe stated one (1) year coverage under

THIS

WARRANTY

IN

l.l

KL.'
<XUr>l.N(;
OK

MKRCIIANTAIIIUTY

I'l

HI'O.SK.

I.NCI.I

IHN<;

TIM.

DAM

No

]MTMin

lialiililt

on

of * Inuu.

ami no

liuhililies

..n ihe Seller's

>urh

Sell.

r.

nrigmal

drfwlft

in.

motrriol

under this

worrnnty.

on examination

Onan's

charges

including

OK ALL

WITHOUT

ANO AM.

LIAHILITY

ACK.

i> aulhoriied lo pi\e any other warranty or lo a*<iume any

Onan's

nhall

factory or one of its Authorized Service St a

prepaid, not

wrvic*.

Such defective part

lahor (in

AM)

ON.AN'S

VIARK.ANTIK.S.

LIMITATION.THK

AND K ITN

OTIIKH

KOK

(..-half

unh-**

jiernon

ii>

uulhorized io pive anv warranlv oi

l.ehalf

WARRANTY

iiAt-r.

thai tar.b product of itn ma

onH

fnrlory

workmanship if properly in*

repair nr replace, as Onan may elect, any

diocloae to

Onan's

fintisfaction

hiler

than one f I)

year afler the produci

will

accordance

OII

OIII.I<;ATIONS

INCIDKNTAI.

made

unle«

he repaired or replaced

wilh

rates

approved hy Onon)

thin

warranly.

LIGATION

I'H

KSSK.I)

IMIMJKI)

KSS

KM u med'

TMKRF.l'NDK.H

OK

KOH A

OR

AND

in

wrilinp

KX

or a

made' or a^nmed in

W.ARRANTIKS

I.1ABILITIKS.

mi

fact

u

Onan's

lo hove

.ihall
linns,

hy an

writinp

IS

IN-

olhei

fKhr.

hy

I.MPUKO.

PARTICULAR

CONSKQt'KN-

ONAN

SPECIFICATIONS

Nominal

Number cylinder (vertical
Displacement (cubic inch) 140
Cylinder
Piston stroke 3 5/8
BHP
RPM

RPM
Compression ratio 19:1
Battery
Batery

Battery

*Oil

Cooling
Generator cooling air
Combustion

Total

Diesel
Maximum

Power
Injection
Output
Output
Rating

AC
AC
Revolving

120/240­Static type exciter (Magneciter) : Yes

dimensions of generating set (inches):

Height

26 11/16

Width

20 5/16

Length

'. 513/8 :'

Weight

(approx. lb.) '.

in-line)

bore < , 31/2

at 1800 rpm : 33.3

(for

60

hertz)

1800

(for 50 hertz) 1500

voltage (AC set, except dual purpose)* 12

size

(AC set, except dual purpose)

SAE

group

IH-two

Amp

- hr, SAE 20 - hr (nominal) 120

charge

capacity in U.S.

cu. ft. per min. of air required 208

fuel

take-off

is rated at
is rated at 0.8 power factor
(output in watts)

AC,

AC,

voltage regulation
frequency regulation in % .• 5

rate

water

flow

air

(CFM

lift

(maximum feet) .' 6

recommended power

limit

pump

(Am.

50hertz set ., 12,000

60hertz set , 15,M0

field

type

volt

single

in

series

amperes

quarts - Refill

(gallons per minute) . ' 6

(CFM

at 1800 rpm) : ^ '2

at rated load '. 1 hp .
Bosch type) PSU

unity

power factor load

in t % : ; 3

generator
phase

4

• Yes

(normal) - AC

: .• 6

at 1800 rpm) 136

take-off

, Yes

model reconnectible Yes

from

1-phase

3-phase

:

sets

2 to 5

front

pulley at any load 2 hp

.'. .". .... 865

•"

*

- Plus 1/2 quart for new

•

. 24 and 32volt batteries on certain modifications.

NOTE:

Hertz is a

unit

filter.

of frequency equal to one cycle per

second.

DIMENSIONS

AND

CLEARANCES

All clearances given

All dimensions

CAMSHAFT

Bearing

Bearing

Bearing
End
Cam
Cam

CONNECTING RODS

Large
Small
Clearance, Large Bearing to Crankshaft ' 001 .0033

CYLINDER

Cylinder
Cylinder

CRANKSHAFT

Main
Crankshaft
Connecting
End

Journal Diameter, Front 2.2500 2.2505

Journal

Clearance

Play, Camshaft (in back

Tappet
Tappet Diameter 8730 .8725

Bearing Diameter

Bushing Diameter

Bore 3-1/2
Diameter

Bearing Journal Diameter 2.2427 2.2435

Play, Crankshaft 010 .015

Diameter,

Limit

Hole

Diameter 8755 .8765

Limits

Main

Bearing Clearance

Rod Journal Diameter 2.0597 2.0605

Rear

1.1875

0012 .0037 '

position)

(I.D.)

' 2.0615 2.0630

(I.D.)

. . . 0.9903 0.9906

3.4995 3.5005

007 .039

(Original

in

Equipment) 0030 .0043

at

room temperature

inches unless otherwise specified.

of

70°F.

Minimum Maximum

1.1880

PISTON (Measure

Piston

Clearance to

Piston

Pin

Ring

Groove

Ring

Groove

Ring

Groove

Ring

Groove

PISTON

PISTON

PIN

Length

3.003
Diameter
Piston
Connecting

Ring

Top
2nd
3rd

Ring Width

Top
2nd

3vd

9899 .9901

Clearance Thumb Push Fit

RINGS

Type

Compression

Compression

Oil Scraper & Compression

f 0925 .0935

0925 .0935

*"::: 0925 1 .0935

90° to Pin)

Cylinder

Hole

Diameter 99005 .99025

Width,

Top 097 .098

Width,

2nd . .0965 .0975

Width,

3rd 0965 .0975

Width,

4th 1895 .1880

Rod Bushing Clearance 0002 .0007

Wall

below Oil

Ring

Groove 0055 .0075

2.988

Minimum

STARTING

Rotation
Pinion
Pinion

to

Armature

MOTOR

" . . . . Counterclockwise

Clearance to
Rest Position — Distance

Outer Edge of

Pinion

Pinion

Stop (Solenoid Plunger Bottomed) .070 .120

from

Pinion

Housing

Mounting

Face

1-9/32

End Play .005 .030

Test Specifications

No

Load v.; 10 volts -

Stall

Torque 4 volts - 420

Brush

Spring Tension 32-40

Maximum

1-15/32

80

amps

5000

rpm

Min.

amps

7.8 lbs.

ft.

Min.

ounces

with

new

brushes

VALVE,

INTAKE

(Hardened

Chrome

Alloy)

Stem Diameter .3405 .3410

Clearance in Guide '. . . . . . .0015 .0030

Valve

Face

Seat

Angle

. . . 42

Valve

Clearance .017

VALVE,

EXHAUST

(Hardened

Chrome

Alloy)

6

Stem Diameter 3405 .3415

Clearance in Guide " . . . .0030 .0050

Valve

Face

Seat

Angle

Valve

Clearance .017

45°

ASSEMBLY

TORQUES

AND

SPECIAL

TOOLS

TORQUE

Center
Connecting
Cover-Rocker Box 8-10
Cylinder
Exhaust
Flywheel
Flywheel
Fuel
Gear
Glow

Injection

Injection
Intake
Oil
Oil
Oil

Rear Bearing Plate 4045
Rocker
Rocker
Thru-Rotor-Stud

*

- This torque is

SPECIFICATIONS

Main

Bolt

97-102

Rod

Bolt

27-29

Head

Bolt

44-46

Manifold

Mounting

Hub Nut 17-21
Pump
Case

Plug 10-15

Nozzle

Pump

Manifold

Base

Mounting

Filter

Hand

Pump

Mounting

Arm

Arm

locks

the nuts in place. The rocker arm nuts are for

adjusting

CAUTION

Nuts 13-15 •

Screw 65-70

Mounting

Cover . 18-20

Nut 4-10*

Stud . ... 35-40

Screws . 15-20

Mounting

Mounting

13-15

Screws 45-50

Screws 15-20

Nut 55-60

friction

valve lash.

Tighten nuts evenly

damage.

FT.-LB.

These

tools are available

repair

work.

Crankshaft Gear

Diesel

Compression Tester 420-0283

Diesel

Nozzle Tester 420-0184

Diesel

Pintle Nozzle Cleaning

(Includes

Driver,

Front Camshaft Bearing 420-0252

Driver,

Rear Camshaft Bearing 420-0251

Screws 20-21

Screws 15-16

Tight

between the

+ 1/4 to 1/2

threads

to

avoid manilold

Turn

only

and

Driver,

Center Camshaft Bearing 420-0254

Driver,

Main

Driver,

Valve

Oil

Seal Guide and

Ridge

Reamer 420-0260
Replacement Blade for 420-0260 420-0261
Valve

Seat

Replacement Blades for 420-0272

SPECIAL

injection

Bearing Front and Rear 420-0269

Seat

Remover 420-0272

TOOLS AND EQUIPMENT

Pulling

nozzle centering

420-0270

Driver

from

Onan to aid service and

Ring

420-0275

Tool

Set

tool)

. . . 420-0208

Rear Front 420-0281

4

20-0274

Assembly

stripping
estimate the
a wrench of normal length.

Special Place Bolts do not require lockwashers or

Never

will

often.

torques

threads. If a torque wrench is not available,

attempt to use a lockwasher

defect their purpose. Check all studs, nuts and screws

Tighten as needed.

assure

degree

proper tightness

of tightness. Use

without

reasonable

with

these

danger of

force and

gaskets.

bolts, it

GENERAL

Proper

installation

points:

adequate

lated

air;

adequate

cooling

water;
exhaust
sturdy
service.
installation;
For
Bulletin T-021.

Each
cuted
the

booklet
(NFPA No. 302)
Association
be helpful to the

gases;

and flat floor; and

Use

refer

more

complete

installation

in

compliance

installation.

entitled

International,

is

very

generator

fresh

discharge

electrical

this

manual

to Typical

instructions,

must

be

with all

The

advice

Fire

Protection

offered

installer

important.

cooling air;

induction air;

of

circulated

connections;

accessible

as a

guide

Installation,

request

considered

regulations

and

guidance

Standard

by the

of

Boston

equipment

National

10,

INSTALLATION

Consider

water;

individually and

Massachusetts,
in

the following

discharge

adequate

discharge

fuel

connection;

for

operation

to

help

Figures

Onan

which may

contained
(or Motor

Fire

Protection

vessels.

of circu-

engine

of

and

with the

2 and 3.

Technical

exe-

affect

in the
Cralt:

will

CAPSCREW

LOCK WASHER

FLAT WASHER

SNUBBER

"GENERATOR OR

OIL BASE MOUNT­ING FOOT

CUSHION

MOUNTING SPACER

BUSHING

'-DRIP PAN

FIGURE I. MOUNTING CUSHION

LOCATION

Select a location

main

keel,

lying

vapors

for

minor

servicing

lubricating oil and the cooling

WATER LINE

for the unit,

which is dry,

and

splash

from the bilge.

operations,

properly

preferably

draining

near

ventilated,

Provide

of the

the

vessels

above

low

accessibility

crankcase,

system.

EXHAUST HIGH WATER TEMP-

ERATURE CUT OFF SWITCH

SUPPORT

MUFFLER

RUBBER

EXHAUST

HOSE

MOUNTING

The floor

set

(Figure

mounts.

A

2-1/2 inch
rocking on its
flexible

trical

wires.

.^LOAD

<LWATER

LINE

should

1)

mounting

clearance

exhaust

be flat and

give

points.

around

mounts

without

line, fuel line,

support

The unit

the unit is

restraint.

batteiy

directly

will

required

Use

cables,

under

the

rock

on its

to

permit

adequately

and

elec-

VENTILATED

BATTERY BOX

FIGURE 2. TYPICAL INSTALLATION

Recommended fluah type thru-hull

fitting and water filter.

TO GENERATOR SET

SEA COCK

STRAINER

WARNING: Do not use scoop type water inlet fittings

on generator sets using Aqualift muffler systems

v—

FITTING

FLUSH THRU-HULL

CAUTION

Install Siphon Break Kit #155-0950 il

exhaust injection elbow is below load
wa'er line. Locate the Siphon Break at least 12inches
above load water line and in a vertical position. Remote
mounting the siphon break is permissible within a 5 loot
radius ol water injection exhaust elbow. Vertical position
and height ol valve must be maintained.

-HANSER STRAPS

Sf| VACUUM RELIEF VALVE

ADAPTER

/""ELBOW (2)

' RUBBER HOSE

WATER OUTLET

EXHAUST WATER

INJECTION ELBOW

SIPHON BREAK •

Install two
or

both

sides).

maximum
Onan

noise

"Sound
enclosure
(Figure

2).

ternal

lines

noise

to a minimum.

noise

reduction

available.

(See detail)

Make provision for passage of air beneath

muffler to prevent condensation. .

hold-down

Secure

reduction

Shield"

which

completely

Openings

and

wires.

methods

NOTE:

clamps

the

to the drip pan (front and

clamps

on

Onan

which is an

surrounds'the

are

provided

Internal

Contact

your

and the

to the

MDJF

insulated

for

connection

air

ducts

local ONAN

special

FIGURE

mounting

units,

generating

reduce

kits

3.

TYPICAL

rear

base.

For

install the

fiberglass

set

to all ex-

air

borne

dealer

for

which are

TYPICAL

BELOW

WATER

INSTALLATION

INSTALLATION

shut-off
another

each

If

fuel

fuel

valve
engine,

to

avoid

lift

pump

LINE

TYPICAL

at the

use a

starving

must

exceed

at the fuel

ABOVE

INSTALLATION

tank.

WATER

When
separate
the

plant.

6-feet,

supply.

EXHAUST OUTLET

LINE

the fuel

fuel line and

(Figure

tank

4). .

is

shared

return

install an auxiliary

with

line for

electric

FUEL

TANK

If a separate
is

less

than

be

below

fuel

fuel

6^feet

pump

tank

below

is

used,

the fuel

level to

install the

pump.

prevent

tank

so the

The

tank

siphoning.

bottom

top

must

Install a

FUEL

CONNECTION

Connect the fuel line to the fuel pump inlet. Pump is threaded

7/16-24 NPTF (American Standard Internal Tapered Pipe
Thread). Important: Always use llexible tubing between en­gine and the luel supply.

The diesel engine requires a

fuel

return

line.

Install
size opening in the
pump (where the nozzle
the top of the

fuel

—

the

overflow

fuel

supply tank (Fig. 5).

^SHUT

FUEL

PUMP

RETURN

LINE

fuel

fuel

fitting

return

FUEL

TANK

BELOW

supply

line

and a

return

line

from

located on the

line

is also connected) to

FUEL

LEVEL

separate

the 7/T6-24

injection

•

FUEL

RETURN

LINE

Do

not use galvanized lines,

fuel

system. Carefully clean all
before putting the plant into operation. Any
ination

may

cause

major

OIL

DRAIN

damage

fittings,

fuel

to the

or

fuel

tanks in the

system components

dirt

or contam-

fuei

injection

system.

The oil drain may be extended to suit the installation. The
oil

base

has a 1/2" pipe tapped hole.

VENTILATION

The generating set requires fresh air for combustion and
generator

cooling.

Onan recommends that the ventilation
system be able to deliver 1-1/2 to 2 times the air required
b;

the set. When the ventilation system

or

boat motion, use powered

tion

when the boat is not in motion. For more

refer to Onan Technical

exhausters

Bulletin

T-021.

depends

on

wind

to provide ventila-

information,

EXHAUST

WARNING

^Pfpe exhaust gases outside

I - exhaust gases

are

poisonous!

See Installation, Figures 2 and 3. The engine exhaust
connection is

1-1/2"

pipe tapped.

of the

hull

PROPULSION

ENGINE

FIGURE

4.

RETURN

LINE

FUEL

GENcKATOR'

LINE

ARRANGEMENT

CONNECT

FUEL

LINE

(Flexible

RETURN

HERE

Line)

Install a separate

1.

Above vessel load water

2.

Pitched downward to prevent water backflow.

3. Shield

4.

Use

line

flexible

5. For turns use sweeping

6.

Increase

Provide a tee for water
haust

(Figure 3) - refer to Water Discharge

Instructions.

line

high

enough to prevent water backflowing into

exhaust

line

as

follows:

line.

near

combustible material.

hose

or tubing.

(long

radius) elbows.

one pipe size for every 10 ft. in length.

line

connection for wet ex-

Raise

the dry portion of the exhaust

the engine under all conditions.

The water jacketed exhaust
at both

ends

for convenience in exhaust

manifold

is pipe tapped

line

conn-

ection.

Line

FIGURE

5.

FUELSYSTEM

AQUALIFT

The

Aqualift
above or below water
exhaust

MUFFLER

is a

systems

(Optional)

highly

efficient

line

are used.

Because
customers must provide the brackets,
quired

for installation.

10

marine

muffler

designed for

installations when water cooled

of installation variables,

hoses

and clamps, re-

IMPORTANT: DO HOT USE SCOOP TYPE WATER INLET
FITTINGS when installing an Aqualilt mulller. Forward lacing

scoops develop sullicient ram pressure to lorce water past

the set's water pump, Hooding the exhaust system where it
may (low back, Hooding the engine cylinders. This can
happen only il the electric set is not running and boat is
underway.

1.

Secure

the muffler to the

ten-feet

brackets

such

may be

of the

as wood

used

muffler to

(Figure

prevent

engine

6) or

blocks

if so

desired.
condensation.

predetermined
exhaust

other

suitable

or

metal

straps.

Allow

OUTLET

outlet)

mounting

for air

location

using

Flexible

passage

(within

"L"

devices

mounts

under

SHORT NIPPLE

DOUBLE TAPPED

TANK BUSHING

LONG NIPPLE -p

, (INSIDE V .

r

NOTE: LONG NIPPLE GOES INSIDE TANK

FIGURE 7. AQUALIFT MUFFLER

MUFFLER)

REDUCER PIPE

BUSHING

SHORT

NIPPLE

NOT TO

EXCEED

1 INCH •

•L"

BRACKET

(MINIMUM

OF 3)

FIGURE 6. SECURING THE MUFFLER

pT^Cjrr^ Do not
LA55-A-PAA^ X above

muffler

when

installing

<

j£i LOCK WASHER

jg*-

NUT BASE

drill

holes

the

higher

extreme

lower

than

edge

mounts.

one inch

of the

3..

Connect

upper
bracket
may be

tions.
(i.e., a
between
Muffler
necessary.
tween
water
crease

feet
necessary

4.

Connect

haust

must

while at

the

exhaust

line to the muffler

elbow. A conventional

may be

used

There

2-1/2"

may be

the

from

of one

of

exhaust

outlet

be

used

in

place

must

drop

the

engine

mounted

A minimum

engine

washing

standard

from the muffler to the

to

prevent

the

exhaust

on the

positioned

anchor

or

to

hang

of flexible

be a pitch of

for a 5' run) in the

exhaust

drop

exhaust

into the

excessive

line from the

hull.

so

that

under

automobile

the

upper
hose

elbow

below

the level of the

of

one-foot

outlet

system

pipe

size

backpressure.

The

exhaust

a minimum ot

way.

one-half

and the muffler inlet.

on the hull to

for

upper

Important: Be sure all liftings are tight.

outlet

and to the

tail-pipe

elbow.

for

certain

hanger

Rigid

applica-

pipe

inch per foot

exhaust

is

necessary

tubing

engine

if

be-

prevent

(see Fig. 3). An in-

every

ten

running

exhaust

outlet

elbow

to the ex-

on the hull

water

will

outlet

enter-

is

2.

Connect

the

tance
the
four-feet

the

engine

from the

exhaust

(see

exhaust

and to the

base

tubing

Figure

line(l 1/2" )to the

exhaust

inlet on the muffler. The

of tHe muffler to the

from the muffler

outlet

3).

marine

upper

must

not

elbow

elbow

exceed

on

dis-

on

L^j^^^x^^^i interior

the lile expectancy;

11

on the mulller will damage the

protective coating decreasing

WIRE
SIZE

DISTANCE

FORWARD

SLEEPING QUARTERS

#18
#16
#14
#12

to

65 ft.

to

100 ft.

to

150

to

280 ft.

FRONT

ft.

MOMENTARY CONTACT

(Onan

SWITCH

No.

308-0155

or

equal)

PILOT'S

STATION

GENERATOR

DRAIN BLOCK HERE

RUBBER HOSE

(LINE FROM WATER

SOURCE)

1/2" I.D.

OR LARGER

~~

PRIMING

PLUG

7 REMOVE PUMP COVER

TO DRAIN

LOOSEN LINE

TO DRAIN

EXHAUST

MANIFOLD

STARTING

MOTOR

BATTERY

NEGATIVE:

FIGURE

DRAIN

HERE

8.

FILL

AND

DRAIN LOCATIONS

12

6 VOLT

BATTERIES

FIGURE

«»

9.

REMOTE CONTROLS AND

CONNECTIONS

BATTERY

BATTERY

Battery

batteiy

CAUTION

will occur alter three minutes while stopped
seconds while running. Alternator windings will
ed almost instantly

belore

Refer to set nameplate for battery voltage. For AC
plants
connected in
battery's positive, Figure 9) for 105 amp-hr, 12
For
batteries and 200 ampere fused

for

connections.

Connect the battery positive (+) to the starter engaging

solenoid
tive

WATER

A

continuous supply of

water pump

Use a section of

vibrations.

1/2" or larger. Use permatex or other pipe
pipe
should
Measure the discharged water

to

assure

on

pipe runs longer than 5-ft. by using larger inside dia­meter
no bubbles
lubrication

strainer in the water suction
for

cleaning.

CONNECTION

requires negative ground. Do not attempt to

polarity

the

with

AC plants

(-)

to a good ground on the engine. (Figure 9).

SUPPLY

fittings

deliver 6 gallons of

plumbing.

on

these

sets.

Refer to set

11

the

battery

is

connected

circuit with

il

resistor.

12

volt

system, provide two 6

series

(one battery's negative to the other

with

32

terminal post. Connect the fcattery

LINE

inlet

is 1/4" pipe thread to 1/2"

flexible

The inside diameter of the plumbing must be

in supply

the supply

appear

and shortens

line

To prove suction

in discharged water. An air leak

the

wrong polarity, damage

battery charging circuit

volt

system, provide 32

switch,

(FIGURE

line

is large enough. Reduce resistance

life

8)

cooling

water is required. The

hose

near

to pump.

cooling

flow

line

of pumps impeller.

line

inlet

to the

see

the set to absorb

Normally,

water per minute.

after thermostat opens,

is air

and where accessible

wiring

or in

be

is

volt

volt

volt

wiring

hose

sealer

tight,

change

diagram.

charging

live

damag-

shorted

batteries

source.

set of

diagram

nega-

coupling.

on all

the pump

see that

reduces

Install

a

REMOTE

For
connect the remote
off

set

heat
momentary contact
jumper
wiring.

LOAD

The set nameplate shows the electrical output rating of the

set in watts, volts and hertz. The set
the electrical circuits and connections
for

Meet
should
because

The set
to

accommodate load wires. Use
stranded load wires
sufficiently
wire

each load
the set
wires.
the grounded (-i-) generator lead and load

a fused main
erating
wrong

the connections at any two generator terminals.

Balance . All

not

exceed nameplate
the generator windings.
output

Single

combination
be used at the
one output lead

rating.

START - STOP

re mote

type) to the terminal block marked B+, 1, 2, 3, in the

control

circuit

the available output voltage.

all applicable electrical code requirements.

ends

control

box using

requires an extra

between terminals 3 and H before

WIRE

CONNECTIONS

be done by a

the installation

control

control

Use a

set and load (Figure 11). If a test run indicates

rotation of 3

leads.

Phase

box

large insulated wires. Strip insulation

as

necessary

wire

to the proper generator output, lead inside

box. Insulate

bolt

switch

phase

Loads: Cunent for any one output load must

Loads

of single

same

does

SWITCH

starting and stopping, use 3 wires to

switch

(SPDT,momentary contact, center-

wire

sizes

switch

(OPTIONAL)

as

listed

in Figure 9. Pre-

wire

to terminal H and

(SPST) connection. Remove

installing

remote

(AC)

wiring

diagram shows

necessary

Also

see Figure 12.

qualified

will

(junction

near

the set to absorb

for clean connections. Connect

(through the

(or

circuit

motors in the load

rating.

Divide

on

phase

time as

not exceed the generator nameplate

serviceman or electrician

be inspected and approved.

box) has knock out sections

flexible

vibration.

bare

ends

of ungrounded

control

breaker) between the gen-

Overloading can

the loads equally between

Three

Phase

and three

long

box) to connect

circuit,

Generators:

phase

as the current for any

for the

Work

conduit and

Use

from

wire.

Install

switch

damage

Any

loading can

GENERATOR

FUSE

OR

BREAKER

TO LOAD

CIRCUIT

FIGURE

120-V.

II.

DOCKSIDE

GROUNDED

UNGROUNDED

POWERSOURCE

13

CURRENT

CURRENT

THESE

DOCKSIDE

CARRYING

CARRYING

LINES

POWER

FROM

SOURCE

CONDUCTOR

CONDUCTOR

^

Output

Lead Markings: Generators are marked Tl, T2, etc.

These

identifying

Voltage
tors:
volt 3 wire;
(Figure

Load
the load connections for the output shown on your
nameplate.

Delta

tap between Tl and T2. The To lead is normally not

grounded but can be grounded if required (Figure
Single

2/3 of

Selection on Reconnectible Single

These

12).

Connections: Refer to the

Generator: Generator lead To is the generator center

phase

full

marks also

models are reconnectible for use as a 120/240

a 120

volt 2 wire

power at center tapped leg available up to

rated three

appear

or 240volt 2

phase

power.

on the

figure

wiring

Phase

wire

power source

which

illustrates

diagram.

Genera-

set's

12-B).

Do

CAUTION

system. Heat
anti-lreezes) will damage
the neoprene impeller pump

a centrifugal metal impeller water pump (Onan #132-0110
or equal)
the set's power take-oll.

Spec

side.

Discharged
exhaust system water
the
instructions

Fill

to

coolant.

in the hot

A through C: Use an expansion tank in the hot water

water

same

as standard system (Figure 13). Refer to the

for water supply

closed

the proper

cooling

If the coolant is anti-freeze, test it periodically.

not use

water pump

or

soluble

water side. Drive

leaves

inlet.

systems

level.

Add an approved rust

existing neoprene impeller

lor hot

oil (in

the

to the

at

Supply

with

water side

many rust inhibitors

impeller. Always connect

cold water side.

it

heat

exchanger and then to

line

line

in this section.

clean, alkali-free water,

ol

cooling

with a belt from

connections are

inhibitor

and

Use

to the

HEAT

EXCHANGER

This

is a closed

fresh

water
termed
circulated
water, sea water,
system
freezing

salt water problems.

Two

conditions
and (2) Customer installed Onan
details

cooling.

fresh . water, hot water, jacketed water, etc. Water

through the

(with

hazards

from

Onan.

COOLING

cooling

Water circulated through the engine is

heat

cold

water, discharged water, etc. This

anti-freeze coolant) is recommended where

exist or where the owner wants to prevent

prevail:

(1) Factoiy installed

(Optional).

system commonly referred to as

exchanger

only

is called raw

heat

heat

exchanger kit. Get

exchanger,

Install

a new zinc

fresh

water outlet end of

or

as inspection dictates.

l^^y^QlJ^jj

overheating.

Use

1

the hot

"pencil"

high temperature cut-oil switch

(Figure 13)

heat

exchanger, every two months

water side

which

screws

to

protect unit Irom

into

in

14

UNGROUNDED LOAD

WIRE (BLACK)

120

V.

GROUNDED LOAD

WIRE

(WHITE)_JC~""^

120

V.

240

V. —J

120

V.

Tl- T3

-Q

j-^

T2

— (JOIN

UNGROUNDED LOAD WIRE (BLACK)

UNGROUNDED LOAD WIRE (BLACK)

AND

GROUNDED LOAD WIRE (WHITE)

oe

(JOIN)

T4

-

GROUND)

o

<Q
ae<

LU

O

UNGROUNDED LOAD

WIRE (BLACK)

T

OT..T4.?<

]

GROUNDED LOAD

. WIRE (WHITE)

o

(JOIN)

T2

2s

o

Tl

O

t-

u>

<Q

2

-

«<

O

"JUi

-i

Z—'

ui

T4

O

(60 hertz1 model

3

PHASE

NAMEPLATE

(HIGHER

VOLTAGE)

A = N ameplate lower voltage,! phasecireuit

B = Namepiate

x

(60 hertz

higher voltage

120/208

volt model has code

AAA

j , rGROUNDED LOAD WIRE (WHITE)

I Phase, Reconnectible Generator

has

code

-3C

gives 2 wire

UNGROUNDED LOAD WIRE (BLACK)

UNGROUNDED LOAD WIRE (BLACK)

^UNGROUNDED LOAD WIRE (BLACK)^

k

rn

u

,1

phase circuit

-4)

Y—Connected

3

PHASE

NAMEPLATE

(HIGHER

VOLTAGE)

A

= N a m epl

B = Nameplate

at

NEUTRAL

T

T TO IS THE

A A BETWEEN

e lower vo

higher

voltage,1

LOAD WIRE NORMALLY UNGROUNDED

GENERATOR S CENTER

UNGROUNDED LOAD WIRE (BLACK)

UNGROUNDED LOAD WIRE (BLACK)

UNGROUNDED LOAD WIRE (BLACK)

11

ag e,l p h as e circuit

phase circuit

or 3

wire service)

Tl AND T2

o

2

^

TAP O

On

-OT2

•O

4/1

Tl

Q

<

O

T3

<

oe

LU

TO

5

T0

Ui

Z

73

Ui

o

to

Q

<

O

•—

<

ee

Delta Connected (60 hertz 120/240 volt model

SINGLE
RATED

PHASE

LEG

AVAILABLE

THREE

POWER AT

UP TO 2/3 OF

PHASE

CENTER

POWER

TAPPED

FULL

FIGURE

12.

has

code

-5D)

WIRING CONNECTIONS

15

OUTLET -

RAW WATER

TO

EXHAUST LINE

FRONT CYLINDER

BLOCK CONNECTION

REAR CYLINDER

BLOCK CONNECTION

RAW COOLING WATER

FROM SOURCE

SPECIFICATION

WATER MANIFOLD

ENGINE DRIVEN

WATER PUMP

(RAW WATER)

, ENGINE DRIVEN

WATER PUMP
(RAW WATER)

A THROUGH C

THERMOSTAT

HOUSIN

FILL

CENTRIFUGAL PUMP

(FRESH WATER)

RAW WATER

^ FRESH WATER IN CLOSED SYSTEM

- BLEEDER VALVE

HEAT

EXCHANGER

RAW WATER

DISCHARGE

REAR CYLINDER

BLOCK CONNECTION

""FRONT CYLINDER

BLOCK CONNECTION 'WW FRESH WATER IN CLOSED SYSTEM

—•—• -—- -~ RAW WATER

INLET - RAW WATER

CENTRIFUGAL PUMP

(FRESH WATER)

BEGIN SPECIFICATION

D

FIGURE

13.

HEAT EXCHANGER

16

-HEAT EXCHANGER•
BRACKET

PLUMBING

OPERATION

CRANKCASE

Use an oil
(formerly
least

Sequences
facturer's MS
the Automotive Manufacturer's MS
MIL-L-2104B

tures are lower than
to

a normal

"J"

series

ing

the MS

hours), then

Do

not mix

for

recommended oil

RECOMMENDED

Depends on operating concfitions. Use NO. 2 diesel

best

economy. Use NO. 1 diesel

OIL

with

the API designation CD/SE, or CD/SD

DS) that has

passed

IIA and HIA of the Automotive Manu-

Sequence

Tests

Tests. (DM oil

may also be used when ambient tempera-

30°F.)

level

in the shortest time on a new or rebuilt

diesel engine, use CC

Sequence

change

Tests) for the

to the recommended oil.

TEMPERATURE

Above

32 0F

0oF to 320F

Below

0oF

brands

or

grades.

changes.

FUEL

the

Series

Sequence

3 Test and at

which

has

passed

Tests

and the

To reduce oil consumption

(formerly
first

fill

DM) oil

only

(50 to 100

(pass-

GRADE

SAE

30

SAE

.10W-30, 5W-20, or

10W,

5W-30

SAE

5W-20 or 5W-30

Refer to Maintenance Section

fuel

for

fuel

(a) when ambient tem-

perature is below 320F., or (b) at all temperatures during

long

periods of
Use low sulfur content
filter)

of at
ture. . Keep
Leave

some

INITIAL

START

Check the engine to make

and that

Bleed

fuel

air

light

engine load, (c) if preferred by

fuel

having a pour point

least

10OF- below the lowest expected tempera-

fuel

clean and protected

room for expansion when

sure

system is air- free.

from

fuel

system as

from

filling

it has

follows:

WORK

PRIMING
FUEL
TURN
INJECTION

(ability

adverse

the tank.

been

filled

Disconnect the

TRANSFER

LEVER

FLOWS

LINE

UNTIL

FROM

FITTING

PUMP.

user.

to

weather.

with

oil

fuel

PUMP

RE-

OF

return

line.

See Fig. 14. Operate the hand
diaphragm type
bles in

fuel

connect the

fuel,

flowing

fuel

return

transfer pump

from

the

fuel

line.

NOTE:

until

return

lobe is up, crank engine one revolution to permit hand
ing.

When finished, return

position)

Temporarily
Figure
it.

to permit normal pump operation.

removethe plug

10.

Fill

the pump

Replace plug before operation.

priming

with

lever

from

the water pump

water to lubricate and prime

priming

lever on

there are no air bub-

line

fitting.

Then

If the camshaft pump

prim-

inward

(disengaged

inlet

fitting.

STARTING

(1)

For

cold

engine starting above 550F,

fold

heater
switch
gine
at

least

switch for one minute. (2) Push START-STOP

to its START position. (3)

starts

and

reaches

speed.

(4) Oil

20 psi (pressure-relief valve is not adjustable).

The most common failure to start is
out

of fuel—and then not properly bleeding the

before attempting to start.

If

the set control has a

after

a shutdown resulting

temperature occurs.

Find

re-set

button, push it to

from

lowoil

the

cause
engine. If continuous false starting occurs, make
centrifugal

switch (Fig. 16)

closes

The adjustable resistor slide tap (in the charging

is

set to give approximately a

2-ampere
applications requiring frequent starts, check battery specific
gravity

periodically and, if

rate

slightly

it

keeps

stopped.

the battery charged. Adjust

Avoid

(move slide tap

overcharging. The resistor is located in

necessary,

nearer

the generator air outlet.

If a separate
ping

is used, adjust the charge

amperes.

automatic demand control for starting and stop-

rate

This normally

keeps

battery charged even if starts-

occur as often as 15-minutes apart.

depress

Release

pressure

caused

the mani-

switch after en-

should read

by

unit

running

fuel

system

re-set

pressure

or

high

before re-starting the

sure

during

speed

build-up.

circuit)

charging rate. For

increase

the charging

ungrounded lead)

only

when set is

for its maximum 4.5

water

the

until

FIGURE

14.

BLEEDING

THE

FUEL

SYSTEM

Extremes in starting temperatures may require additional
preheating. If engine
several

seconds

preheat

for a longer

r^^TI^rXkr^'?

CAUTION

destroy

the

J .

glow, plugs

and

interval.

not

^

I drear

fails

repeat

to start

starting

quickly,

sequence

rest

WPh overvoltage to the starting

t at any

and air

time. Overvoltage will

heater

in two to

17

engine

applying

three

FIGURE

IS.

OPERATING

CYCLE

seconds.
source
connected

("start
to

II it

ol

AUTOMATIC

Separate
but

must provide engine pre-heating.

The

automatic

glow

plugs and the

before cranking occurs. Remove the jumper in the unit's

control

box

circuit')

the set H

becomes necessary

power

to

start

the

in

parallel.

STARTING

controls may be used for automatic start and stop,

control

which

connects

and connect separate-control pre-heat

terminal

AND

has a time delay relay to pre-heat

manifold

terminal

when

to use an

unit

— use a

additional

12volt battery

STOPPING

heater for about 20-seconds

H (heater) to

installing

the

control.

terminal

circuit

The time

3

delay

relay also delays engagement of the starter when load

is

re-applied before the engine stops completely.

STOPPING

(1)

Push start-stop

(2)

Release

close

fuel

APPLYING

If

practicable,
heavy load. Continuous generator overloading may
operating
generator can safely handle an overload temporarily, but for

normal
exhaust system may

LOAD

temperatures that can damage the

operation, keep the load

switch

valve.

allow

switch

to stop

when

unit

set to

form

carbon deposits

position.

stops. If stop

warm

up before connecting a

windings.

within

nameplate

during

circuit

cause

rating.

operation at

18

fails,

high

The

The

light

loads.

Apply

full

load occasionally before shut-down to

prevent excessive carbon accumulations.

Try

to connect the load in
one time. Most installations use a
closed to connect a portion of the load.

steps

instead of

line

full

load at

switch that must be

9. Shut down

and

hot.

pressure.

10.

Slowly

11.

Fill

open

system to top

unit.

Open

Alter running unit
closed cooling system

the 14 lb.

pressure

with

pressure

cap and check water

coolant.

10

cap

minutes,

is

pressurized

slowly

to

level.

the

vent

EXERCISE

Infrequent
set a

needs

BREAK-IN

The

1.

One

2.

One

3. FulHoad.

Continuous mnning under one
few

hundred hours usually results in poor piston

:

seating, causing higher than normal oil consumption and

blowby.

NOTE: Drain

while

SAFETY

In

case

low

oil
emergency stop, investigate and correct the
re-set

EMERGENCY

MDJF
set battery

an emergency, a battery can be shared

provided

Remove the ammeter

control

the battery

STANDBY

set use results in hard setting. Operate standby

least

30 minutes

charging.

SETS

each

week. Run longer if battery

PROCEDURE

unit

should be run in the

half

hour at 1/2 load.

half

hour at 3/4 load.

the

initial

the

engine

is

still

following

oil

hot.

sequence:

half

load during the

alter 50hours

ol

DEVICES

of dangerously

pressure,

button before restarting.

OPERATION

generating

fails

the set charging

box and

with

this lead

high

coolant (water) temperature or

the

cut-off

sets

completely and set must be operated during

wire

tape

switch

IF

require a battery for running. If the

circuit

connected to terminal No. 8 in the

the

bare

wire

stops

the

BATTERY

is disconnected as

end. The set

disconnected.

FAILS

with

ether equipment

will

unit.
cause.

first

ring

operation

After

an

Press

follows:

not charge

OUT-OF-SERVICE

When

taking

storage

methods must be used to prevent

rosion,

contamination, and temperature extremes.

Fuel

System

1.

Clean air cleaner (if

with

oil.

2.

Cover or

3. Clean throttle linkage (and governor linkage) thoroughly.
Lubricate
not

lubricate plastic

Oil

System

1.

Drain

engine lubricating oil
ice the engine
IDENTIFY

filter

cap.

2.

Rempve

oil

(SAE50 substitute) into

over by hand several revolutions to lubricate cylinder

walls,

pistons, and rings.

3. Remove and service oil

PROTECTION

unit

out of service for 30-days or longer, proper

damage

used)

- do not service air cleaner

Check and clean air intake.

seal

exposed air intake openings.

metal

ball

joints

with

light

machine oil (do

ball

joints).

while

engine is warm. Serv-

with

proper oil. TAG the engine to

the lubricating oil installed.

fuel

injectors. Pour 2

filter.

each

Install

ounces

cylinder. Crank engine

injectors.

Secure

of rust

from

cor-

the oil

inhibitor

HEAT

EXCHANGER

Improper

of
these
exchanger:

filling

the engine. Therefore, to prevent this possibility,

instructions whenever adding cooling to the

1.

Remove

2.

Open

3. Remove vent

4.

Fill

5. Close

6. Replace vent

7. Replace

8. Operate

fill

fill

with

fill

fill

unit

vent valve

(OPTIONAL)

of the

heat

cap.

plug.

coolant.

vent valve

plug.

cap.

.10 minutes at

exchanger can

(turn

counterclockwise).

(Spec

A through C).

(turn

clockwise).

(Spec

A through C).

full

FILLING

cause

overheating

load, watch for leaks.

follow

heat

19

Cooling

System

1.

Drain

entire cooling system

haust

manifold

or

keel cooler components, engine cylinder block, and

water pumps.

Generating units equipped
cooling

may be
freezing
components not protected
water intake and outlet lines, etc.).

and exhaust

filled

temperatures are expected.

including

line.

with

with

a good quality anti-freeze if

from

freezing (exhaust lines,

water cooled ex-

Drain

heat

heat

exchanger or keel

Drain

only

exchanger

those

WATER

MANIFOLD

FILL

VALVE

VENT

Whenever water
bolt,

end cap and

flow

is restricted, remove the 1/2-inch

gasket

at the
exchanger and clean the water
water intake for

Electrical

1. Clean generator brushes
clean,

2.

Clean static exciter

dust and

seaweed,

System

dry,

and

lint-free cloth. Do

dirt

deposits in

grass,

Batteries

and

with

control

etc.

Not

dry low-pressure air. Remove

3. Disconnect batteries and remove

batteries by maintaining

liquid

charger to maintain voltage.

CAUTION

STORE

ALL

TION

AND

Discharged batteries

3

damage

BATTERIES

MAINTAIN

CHARGE

if

exposed

IN A

FULLY

DURING

General

1.

Cover or

seal

all exposed openings (exhaust outlet,

water ports, etc.)

2.

Cover entire generating plant.

TAG

and

IDENTIFY

QUIRED

all

BEFORE

items requiring attention and service

unit

to indicate SERVICE RE-

ATTEMPTING

tion

NOTE:

Aqualilt muffler requires no out of service protection.

RETURNING

1.

CHECK

THE

SET

SERVICE

TO

OPERATION

IDENTIFICATION

service the plant.

2.

Uncover and remove

move any dust,

3.

CHECK

(drain

moisture
fuel
haust

fuel

tanks if necessary).

or contamination

line

connections, all

line

connections.

dirt,

storage

or

seals

foreign

supply tanks for moisture accumulations

CHECK

(drain

wiring

HEAT

EXCHANGER

FIGURE

front

passages,

slip rings

15-A.

end of the

Check raw

by

wiping with

heat

Lubricate These Parts.

box and

level

are

to

junction

from

vessel. Service

and using a

subject

to

boxes.

trickle

severe

freezing temperatures:

CHARGED

CONDI-

STORAGE.

TO OPERATE.

prior

to opera-

TAGS

to properly

from

entire

unit.

matter.

lubricating

if necessary).

oil for

CHECK

connections, and ex-

FILLING

a

List

Re-

EXPANSION

HEAT

EXCHA?4GER

4.

Service air cleaner (if used). Torque

and bleed
are

found

sediment

5. Service

fuel

in

fuel,

bowl).

cooling

system (if moisture or contamination

replace

system

filters

and clean

with

clean fresh water. Prime

fuel

water pump and see that all air is bled
system. If anti-freeze was

system, check

6. Check entire

level

unit

for water,

left

in closed type

and service as required.

fuel,

or oil leaks. Conect

leakage as required.

7:

Install

8.

Start

HIGH

1.

See that nothing obstructs air

2.

Keep

LOW

1.

Use correct SAE No. oil for temperature conditions.

2.

Protect

3. Keep batteries in a

4.

Partially restrict

fully

charged batteries.

the set in normal method.

for leaks, correct

voltage

Check

the running set

output, proper cooling.

TEMPERATURES

flow

to-and-from

cooling

closed system

system clean.

cooling.

Maintain

water

TEMPERATURES

Change oil
temperature drop
to

a warm location or apply heated air (never an open

flame)

only

when engine is warm. If an unexpected

causes

externally

fuel

until

against moisture condensation.

cool

an emergency, move the

oil

flows

well

charged

air

flow

freely.

condition.
but use

care

overheating.

5. Add good

quality

anti-freeze if

danger

of freezing

exists.

NOTE: Aqualift muffler need

DIRTY

CONDITIONS

1.

Keep set clean. Keep

2.

Service air cleaner (if

3. Change

4.

Keep oil and

crankcase

fuel

not be

drained

cooling

system clean.

used)

as frequently as

oil every 50 operating hours.

supplies in dust-tight containers.

5. Keep governor linkage clean.

6. Clean generator
do not remove normal (dark brown)

brushes,

slip

rings, and commutator -

film.

Do not

TANK

injectors

fuel

pump

from

cooling
cooling

the set.

level-

in

unit

to

avoid

necessary.

polish.

20

ADJUSTMENTS

CHECK

CENTRIFUGAL

Refer to Dimensions and
tances.

Replace burned or

If

only

sligjitly

Measure gap

The

centrifugal

Loosen and move stationary contact to correct gap.

NOTE: Rotate engine cranks&alt
clockwise before adjusting points.

forces created

wrench

on the

burned,

with

switch is wide open when engine is stopped.

by the

flywheel retaining screw.

BREAKER

Clearances

faulty

dress

smooth

thickness

gauge

water pump impeller.

POINTS

for correct gap dis-

points.

with

file

(Figure 16).

a few

To

degrees counter-

release

any

Use a

or

fine

torsional

stone.

socket

GOVERNOR

The governor controls engine
age

appear
Engine
generator, thus ISOOrpm is 60hertz.. The
not

vary, more than 3 hertz
ation.
operate

Speed
the spring tension by turning the governor spring nut (Figure

18).

Turn

RPM

and counterclockwise to reduce governed

a tachometer against

meter.

Sensitivity
(no-load
justing
sensitivity

clockwise

on the nameplate (see also Specifications).

speed

equals

Be

sure

smoothly.

Adjustment: To

the nut clockwise (more spring tension) to

Adjustment: To adjust governor sensitivity

to

full-load

ratchet (Figure 18). Counterclockwise gives more

(less

gives

frequency

throttle, linkage and governor mechanism

flywheel

speed

speed

less

sensitivity (more

speed.

from

change

droop),

drop when

Rated

speed

multiplied

no load to

the governor

cap screw or use frequency

by 30 on a 4 pole

turn

the sensitivity ad-

full

load is applied),

speed

and

volt-

speed

should

full-load

speed,

drop). If the

change

increase

speed.

oper-

Hold

governor is too sensitive, a rapid hunting condition occurs

(alternate increasing and decreasing

maximum

justment, the

ing

IMPORTANT: Excessive droop
misfiring. Correct this condition before adjusting governor.

VALVE

Check valve
ture (about

1.

•

valve push rod

sensitivity

speed

the governor,

without

will

secure

hunting.

require readjustment.

lock

nut.

CLEARANCE

clearance

70°

F).

Turn

the

flywheel

its

valve adjusted is on its compression stroke. Use a

socket wrench on the

To

determine if the cylinder is in its compression
stroke, observe the action of the push rods as the
engine is rotated in a clockwise direction. The exhaust

intake valve push rod
piston

reaches

mark

should be aligned

valve

push rods stationary.

when the engine is at room tempera-

until

the cylinder

flywheel

will

be in its lowest position and the

will

be moving downward. As the

top dead center, the

with

speed).

After

sensitivity ad-

may be

screw hex head.

the

which

timing

caused

flywheel

pointer and the

Adjust for

After

adjust-

by

engine

is to

have

timing

FIGURE

16.

CENTRIFUGAL

CENTRIFUGAL

SWITCH

BREAKER

SET

POINTS

GAP AT

.040"

SWITCH

21

A883

FIGURE

.

17.

SETTING

MAXIMUM

STOP

STOP

SCREW

GOV ERNOR

ARM

SENSITIVITY

ADJUSTING

RATCHET

GOVERNOR STUD

\

DECREASE

SPEED

DECREASE

SENSITIVITY

2.

Now turn the

45degrees.

it

must be estimated.

position,

it

completely closed.

3. To

change

locknut

which

head

(see Figure 19). Loosen the locknut to

clearance

and tighten it to

flywheel

There is no

will

clockwise for an additional 10 to

timing

mark for this position so

With

the piston located in this

be in its power stroke

the setting of valve

secures

the rocker arm to the cylinder

reduce

FIGURE

with

clearance,

clearance.

18.

GOVERNOR ADJUSTMENT

both valves

adjust the

increase

.INCREASE

SPEED

•SPEED

ADJUSTING

NUT

4.

Using a feeler

gauge,

check the

clearance

rocker arm and the valve (see Fig. 20).

reduce

the

clearance

Correct valve

until

clearance

the proper gap is established.

is .017" intake and .017"

exhaust.

5. Always adjust the valve
(1-2-4-3)

sequence.

adjust #1 cylinder.

the valve

clearance

clearances

After

allowing

After timing

according to

the #1 cylinder, adjust

steps

between the

Increase

in the

firing

order

engine to cool,

2 and 3.

or

VALVE
SPRING

RETAINER

ADJUST VALVE

CLEARANCE HERE^-

FIGURE

19.

VALVE MECHANISM

ROCKER

ARM

22

FIGURE

EXHAUST.

20.

ADJUSTING VALVES

6. To

adjust
the flywheel in a clockwise direction 180
(one half revolution) from the position

timing

be

between

center)

7. After positioning #2 cylinder,
ance

.8.

To

adjust
wheel in a clockwise direction
revolution). The flywheel should be

45-degrees

the valve

#1 cylinder. The flywheel position should

10 and 45

flywheel mark.

according to

#4 cylinder valve

past

clearance

degrees

steps

3 and 4.

the TC (top

of §2 cylinder, turn

past

adjust

clearance,

180-degrees

center)

degrees

used

when

the BC (bottom

the valve

between

flywheel mark.

c'en:.-

turn the

(one-half

10- and

fly-

9. After timing #4 cylinder,
according to

10. To

adjust
flywheel
half

revolution). The flywheel should be

and

45-degrees

mark.

11.

After timing #3 cylinder,

according to

steps

3 and 4.

the valve

in a clockwise direction

steps

clearance

past

the BC (bottom

3 and 4. .

adjust

the valve

for #3 cylinder, turn the

180-degrees

between

center)

adjust

the valve

clearance

(one-

10-

flywheel

clearance

23

GENERAL

MAINTENANCE

FUEL PUMP AND

FILTER BODY

GASKE

BOWL

A725

FUEL

PUMP

CONNECTOR

(From fuel

transfer pump)

SEDIMENT

BOWL

ELBOW

(To injection

pump)

TO INTAKE

MANIFOLD

PULSATION

DAMPENER

ELEMENT

OVERFLOW HOSE

OIL DRAIN-

Replace element inside of pulsation dampener

every 2000 hours.

BREATHER

SPECIFICATION

PULSATION

BLEED

SCREW

DAMPENER

A AND B

COVER GASKET

DRAIN

DUAL FUEL FILTER SYSTEM-BEGIN SPEC B
Drain water periodically as required. Replace primary
filter every six hundred (600) hours. Perform more often in
extremely dusty conditions. Replace secondary filter with

every Sth change of the primary

Y—^^^^^^ Drain plug on fuel filters can tolerate

(^CAUTION^Jon|
two wrenches in combination for breaking plug loose and
for final tightening.

DUAL

|jmjted amount of torque. Use

y a

FUEL

RY SE<

PRIMAR

FILTER

filter.

FILTER

SECONDARY

FILTER

DRAIN

FIGURE 21. SERVICING PROCEDURES

FILTER

ELEMENT

SECONDARY

24

DRAIN

PLUG

FUEL

FILTER

•BODY

(Spec.

A Only)

IMPELLER

Tighten Screws

IS

to

COVER

COVER GASKET

17

in.

lbs.

GASKET

AIR

INLET PORT

MANIFOLD

HEATERS

RESONATOR

RESONATOR

INTAKE

MANIFOLD

WATER

PUMP

CAP AND OIL

LEVEL INDICATOR

KEEP OIL

AT THIS LEVEL
NEVER OPERATE

ENGINE WITH OIL

BELOW THIS LEVEL.

OIL

LEVEL

ALWAYS REPLACE

A874

CAP TIGHTLY, OR
OIL LEAKAGE MAY
OCCU R.

INDICATOR

BALL

JOINT

BREATHER

CLEAN

BALL

JOINT

Remove breather cap. Remove baffle and wash

in suitable solvent. Dry and reinstall.

CRANKCASE

SPECIFICAtlON

FIGURE 22. SERVICING PROCEDURES

25

CAP

TUBE

TUBE

FROM

AIR

CLEANER

BREATHER

TUBE

BAFFLE

BREATHER

A AND B

2 9/32"-

The

raw

is protected from corrosion
mounted
heat exchanger. Inspect
every . 2
to less than

water side

on

pipe plugs

months

1/2

of the

in one end of the

and

the

replace

original size.

T

heat exchanger
by

zinc pencil

pencil

at

if

least

deteriorated

SPECIFICATION A THROUGH

ZINC PENCIL

FIGURE

23.

SERVICING PROCEDURES

GENERATOR SET

Before
components for mechanical security. If any abnormal
condition,
detected, repair or service as required. The
set should be kept free of dust,
fuel.

WHAT

TO

Engine oil

Engine

fuel

CHECK

Check
on

Check

HOW

level

oil

indicator).

level

C

ROUTINE

generator

defective part or operating

Be

sure

TO

(should be at

in tank.

set is put in operation, check all

proper operating procedure is

CHECK

full

mark

CHECK CHART

difficulty

generator

dirt

and

spilled

Add

oil as

mark.

See that

oil or

followed.

necessary

fuel line

is

PRECAUTIONS

to

bring level

is properly connected.

to

full

Engine radiator

Connecting

Battery

cables

Check

ventilating

'

water

level.

Check for proper connections.
Check for physical

Check electrolyte

... 1 -.

openings and

damage.

level.

.'v'«

.

Remove any obstructions. Keep radiator

Tighten
Replace

Keep

Add only

i

I

i

connections.

damaged connectors.

level

above; plates.

approved water as

*' • . '•.

26

full.

necessary.

MAINTENANCE

SCHEDULE

Use this factoiy recommended maintenance
favorable operating conditions) to
get long and
tenance
set. Maintenance is
ATOR MAINTENANCE

efficient

set

life.

can result in failure or permanent

divided

into two categories: (1) OPER-

- performed by the operator and

(2) CRITICAL MAINTENANCE

serve

as a guide to

Neglecting routine main-

damage

- performed by

service personnel.

OPERATOR

MAINTENANCE ITEMS

MAINTENANCE ITEMS

Inspect Unit

Check Water Level (Heat

Exchanger Models)
Inspect Exhaust System
Check Fuel Supply

Check

Oil

Level
Clean Governor Linkage
Change Crankcase

Drain Fuel System Conden-

sation Traps

Check Battery

Replace

Oil

Change Primary Fuel Filter

Change Secondary Fuel

Filter

Empty Fuel Sediment Bowl

MAINTENANCE

Oil

Filter

SCHEDULE

OPERATIONAL
8 100 200

X

X

x6
x3

X

x2

X

x3

X

X

X

(based

to the

qualified

HOURS
600 3000

x3

on

x3

CRITICAL

MAINTENANCE ITEMS

MAINTENANCE ITEMS

Check Slip Rings
Check Brushes
Check Commutator
Check Valve Clearance

Inspect Water Pump F/Leaks

and Wear, Replace

Necessary
Clean Generator
Grind Valves
Clean Rocker

Holes

Check Nozzle Opening

Pressure, Spray Pattern
General Overhaul
Change Fuel Filters

x

Perform as indicated on Table.

xl

Replace

replace commutator

x2

Perform more often in extremely

Lubricate
require
replace the old style metal linkage

ball

x3 Water or foreign material in the

injection

dirt
storage
corrected.
corrections of

x4

This service must be conducted by trained diesel

injection
ties.

collector

the old style linkage. Plastic

only

type in extremely

system. If

in the

facilities

Filter

equipment personnel

Omit

MAINTENANCE

OPERATIONAL

*

*

*

if

(If

Required)

Box Oil

fuel

this service

Line

(If Req.)

x5

ring

brushes

brushes

when

cleaning. It may be

dirty

operating conditions.

daily

pump sediment

inspection shows water or

bowl, fuel

should be checked and situation

elements

fuel

contamination problems.

should be replaced

with

until

SCHEDULE

200 500

X

xl

X

when

these

1000 2000

X

worn

worn

to 5/8".

dirty

advantageous

with

fuel

can

suitable

conditions can

HOURS

5000

X

X
X

X

x4

to 5/16",

conditions.

ball

type

the plastic

ruin

the

handling and

following

test

facili-

be met.

x5 Service per Operator Maintenance Schedule.
x6 With

plant running,

visually

and audibly check

exhaust

system for leaks.

*

Tighten

first

head

bolts and adjust valve

clearance

© hours on a new or overhauled engine.

after

>«

For

critical

Service Manual is available).

items not covered, see

page

2' (A

Major

X

to

27

:-.FUEL SYSTEM ;

Defeciive Fuel System
Air in Fuel System
Incorrect Timing
Restricted Air Intake - Dirty Air Filter
Poor Quality Fuel
Dirty Fuel Filters
Out of Fuel or Shut Off Closed
Worn or Damaged Transfer Pump, Leaking Diaphragm
Faulty Injection Pump, Nozzles or Gaskets

Fuel Line Leaks
Wrong Timing Button in Injection Pump
Wrong Thickness Pump Mounting Gaskets

Run For Long Periods of Time at NO LOAD

••: LUBRICATION SYSTEM

Low Oil Supply
Defective Oil Gauge

Oil Leaks From Engine Base or Connections
Light or Diluted Crankcase Oil
Leaky Oil Seals
Improper Lubricatioi
Faulty Oil By-Pass
Worn Oil Pump
Heavy Oil or Clogged Passages
Dirty Oil Filter

GOVERNOR SYSTEM

Loose or Disconnected Linkage
Binding Linkage
Excessive Wear in Linkage
Incorrect Governor Adjustment
High Spring Sensitivity
Incorrectly Installed Governor Yoke or Cup
Overloaded Generator

Insufficient Coolant

Faulty Thermostat
Worn Water Pump or Defective Seals
Water Passages Restricted
Blown Head Gasket

Overheating

Restricted or Too Long Water Lines
Defective Expansion Tank Pressure Cap

Dirt on Cooling Fins (Air Cooled)

Inadequate Air Circulation (Air Cooled)

Poor Compress
Loose Piston
Loose Connecting Rod or Crankshaft Bearing
Incorrect Valve Clearance
Broken or Weak Valve Spring
High Exhaust Back Pressure
Valves Not Seating Properly
Worn Bearings
Worn Cylinder Walls. Pistons, Rings
Sticking Valves

Worn or Dirty Valve Guides

COOLING SYSTEM :

INTERNAL ENGINE

28

PARTS

CATALOG

INSTRUCTIONS

For

parts or service, contact the dealer

rized

Onan

Parts

and Service Center.

To

avoid

Always

1.

Always

errors or delay in

refer to the nameplate on your

give the

MODEL

filling

and SPEC NO. and

FOR

from

whom

your parts order,

unit:

SERIAL

ELECTRIC

MODEL

SERIAL

NO.

IIIDnDTAUT'

InlrUn

I-nil I

ORDERING

you purchased this equipment or refer to your Nearest

please

furnish

NO.

REPAIR

all

information

PARTS

requested.

PLANT

AND

SPEC.

NO.

ALWAYS

GIVE

'WHEN

ABOVE

ORDERING

NOS.

PARTS

Autho-

For

handy reference, insert

nameplate

2.

Do not order by reference number or group number, always use part number and description.

3. Give the part number, description and quantity needed of each
return

the part prepaid to your dealer or

address

4.

State

promptly

list

Prices are purposely omitted

duties,

For

current parts prices, consult your Onan Dealer,

"En

esta

de los precios,

Consiga los precios vigentes de su distribuidor de productos

plainly

definite shipping instructions. Any

indicates items are back ordered.

sales

lista

on the package.

against the transportation company making the delivery. Shipments are complete

taxes, exchange

de

partes

derechos

from

los precios se omiten de proposito, ya que

aduanales,

this

rates,

Write

etc.

impuestos de venta, cambios extranjeros, etc."

information

nearest

a letter to the

Parts

Catalog

AUTHORIZED

claim

for loss or

diie

Distributor

in the

same

to the confusion resulting

YOUR

spaces

item.

SERVICE

address

damage

or

Parts

bastante

"ONAN".

engine

above.

If an older part cannot be

STATION.

stating the reason for returning the part.

to your

and Service Center.

unit

from

confusion resulto de fluctuaciones

Print your name and

in transit should be

fluctuating

2S

unless

identified,

filed

the packing

costs,

import

This

catalog

items

and are

the

Onan

Key No.

applies

nameplate,

represents

interchangeable

of

the

unit.

to the

identified

select

parts

between

standard

by a

reference

the

that

models.

Parts

differ

Right

MDJF

Generating

number.

Parts

Sets

as

illustrations

Key No. (1, 2, etc., in the

between

and left

GENERATOR

models.

Unless

generating

SET DATA

set

listed

are typical.

last

otherwise

sides

are

TABLE

below.

column)

mentioned

determined

Parts

Using

that

are

arranged

the

applies

in the

by

facing

in

groups

Model

to

and

your

description,

the

engine

Spec

unit.

This

of

related

No. from

Parts

parts

are

end (front)

MODEL

(Formerly I5MDJF-3E3836/)

+ - New model designations shown, begin during 1969. Previous designations did not use a decimal in the KW rating.

** - Set is reconnectible for I20volt, 2wire; 240volt, 2wire or 120/240 volt, 3wire service.

AND

SPEC

NO. •

WATTS

I5.0MDJF-3CR/*
I5.0MDJF-4R/*

I5.0MDJF-5DR/"

I2.0MDJF-53CR/*

I2.0MDJF-54R/* 12000
I2.0MDJF-55DR/*
I2.0MDJF-57R/*

I5.0MDJF-3CR4/* ±
l2.0MDJF-53CR4/» i

I5.0MDJF-3CE/*

EXAMPLE: I5.0MDJF was formerly I5MDJF and I2.0MDJF was formerly I2MDJF.

* - The Specification Letter advances (A to B, B to C, etc.) with manufacturing changes.

NOTE:

Previously the C designation was not used in the model.
i - These units have 32volt DC system for engine requirements only (not auxiliary DC loads).
NOTE:

Hertz is a unit of frequency equal to one cycle per second.

15000 120/240 60
15000 120/208 60 4
15000 120/240 • 60

12000 "
12000 120/240 50 4

12000

15000
12000

Workboat Models - See Special Parts List Followine Standard Parts List.

ELECTRICAL

VOLTS

120/240. 50

120/208 50 4

220/380 50

120/240 60

120/240 50 ** 1 2

DATA

HERTZ

WIRE

**

4

* *

4

* •

PHASE

1 1

3
3

1
3
3
3

1

PARTS

KEY

NO.

1
1

1
1
1
1

2

30

CYLINDER

HEAD,

VALVE

AND

ROCKER

GROUP

REF.

NO.

10
11 509-0090 4

12

14 1 15-0127 8

15
16 114-0152 8

17 1 15-0149 8

18

19
24
25
26

27

28

31
33
35
38

39

40
41
42
43
44
45
46

47

48

50
51
52
53
54
55
56

PART

NO.

1

HEAD,

CYLINDER
110-1854
1 10-1856

2

1 10-1852
1 10-1501

3

4

INSERT, VALVE SEAT (STELLITE)

1 10-1268 8
1 10-1268-02
1 10-1268-05
1 10-1268-10 8

1.10-1268-25

1 10-1320

5

1 10-1278

6
7 1 10-1221 8

1 10-1220 8 Retainer, Valve Spring

8
9

11

0-0858

1 10-0859

ARM,

ROCKER
115-0128 4 Exhaust
1 15-0129 4

115-0150 8

1 15-0195
115-0196
1 1 5-0197
120-0628
115-0130
1 10-1264

800-0501 12

526-0174
520-0608
403-0690
809-0042

PLUG,

GLOW
333-0106
333-0107
333-0112

I 10-0546
520-03 3 8
402-

0361

403-

0890
403-0826
402-0362

123-1140

850-0045

800-0030

526-0130
800-0094
526-0100
800-0038
850-0044
800-0025
862-0015

QTY.

USED

2
2
2
8

8
8

8
4
4

16

8

8
2
2

2
2

10 Screw (3/8-16 x 4-1/4") -

12 Washer, Cylinder Head

8 Stud, Exhaust Manifold

1 Bracket, Lifting
2 Screw, Oil Line, Rocker

INCLUDES GASKET

4
4
4
4
2
2

I

I
2
2
8

Sets Without Heat Exchanger
Sets With Heat Exchanger
Gasket, Head
Guide, Valve

Standard

.002"
.005"
.010"

.025"
Valve,
Valve,
Spring,

Lock, Valve Spring Retainer
Cap,
Seal,

(Includes Retaining Rings)

Intake
Ball,
Locknut, Rocker Arm
Stud,
Rod,

Tappet, Valve
Guide, Push Rod
Cover, Rocker

Line,

Gasket, Rocker Cover

Cylinder Head

Screw (3/8-16 x 3-3/8") -

Cylinder Head

Cover

Key I (l2Volt)

Key I (24Volt)
Key 2 (32 Volt)
Gasket, Glow Plug
Stud,
Cushion,

Brace, Lifting Bracket

Spacer, Lifting Bracket

Bushing,

Standpipe - Begin Spec C
Washer, Lock - Rocker

Cover Mounting

Screw, Hex Cap - Rocker

Cover Mounting
Washer (#10)
Screw (1/2-13 x 2")
Washer (l/2"j
Screw (5/16-18 x 3-1/4")
Washer (5/16"), Lock
Screw (5/16-18 x 3/8")

Nut (5/16-18)

PART

OESCRIPTION

Oversize
Oversize
Oversize
Oversize

Intake
Exhaust (Stellite)

Valve

Valve Stem

Oil - Intake Valve

Rocker Arm

Rocker Arm

Valve Push (Steel)

Oil, Rocker Cover

Intake Manifold

Vibration

Spacer

31

32

REF.

NO.

2

3 101-0386 1 •Gasket Kit, Rear Bearing

4

4A

4B 101-0342 2 •Bolt, Center Bearing Housing
5

6
7

8

8A

9

10

1 1

12
13

14

15 123-0667 1 Gasket
16

17
18

19

20

21

22
23

PART

NO.

I 10-1665

101-0337 ' 1

•BEARING, PRECISION MAIN - FRONT & REAR
101-0359 2
101-0359-02 2
101-0359-10 2
101-0359-20 2
101-0359-30 2

•BEARING HALF, PRECISION MAIN - CENTER
101-0361 2 Standard
101-0361-02 2
101-0361-10 2
101-0361-20 2
101^)361-30 2

526-0035 2 •Washer - (1/2") - Center

104-0420 2
101-0363 1

101-0365 1

101-0364 1

•TUBE,

•PLUG,

CRANKCASE OIL

120-0586 1

120-0585 1 Rear

517-0053 1

CYLINDER BLOCK EXPANSION
(ORDER BY SIZE)
517-0059 As Req.
517-0096 As Req.
517-0097 As Req.

509-0086 1

805-0019 6

TUBE,

OIL FILL
123-0681 1 Spec A Only
123-1086 1 Begin Spec B

CAP AND INDICATOR
123-0698 1
123-1056 1
123-0191 1
123-0787 1

123-0645 1

101-0356 1

123-0865 2

102-0539 1
102-0475 1 Gasket. Oil Base

QTY.

PART

USED

DESCRIPTION

I Block Assembly (Includes

Parts Marked *)

•Plate,

Rear Bearing (Less

Bearing & Pins)

Plate (Includes Shims)

Standard

.002"

Undersize

.010"

Undersize

.020"

Undersize

.030"

Undersize

.002"

Undersize

.010"

Undersize

.020"

Undersize

.030"

Undersize

Bearing Housing

•Washer, Crankshaft Thrust

•Bearing,

•Bearing,

•Bearing,

Front

•Plug,

1-7/16"
1-9/16"

1-3/4"

•Seal,

•Bolt, Rear Bearing Plate

Spec A Only
Begin Spec B
Gasket, Cap
Cap,

Tube,

•Housing,

Baffle,

Base,

Precision Cam

Front (Standard Only)

Precision Cam

Rear (Standard Only)

Precision Cam

Center (Standard Only)

Expansion Rear

Camshaft Opening

Crankshaft Rear

(3/8-16 x

Spec A through B

through B

Bearing

through B

1-1/4")

Breather Tube -

Breather - Spec A

Center Main

Breather - Spec A

Oil

REF.

NO.

24
27
30

32

33

34

35

36
37
42

43
44
45

48 503-0564

49 503-0197

50 123-1045

51 516-0177

52 123-1049

53 503-0563

54 503-0562

55 870-0240

56 505-0681

57 505-0682

58 505-0683

59 503-0170 4
60 WASHER, LOCK

61 SCREW, HEX CAP

- Included in Cylinder Block Assembly.

PART

NO.

505-0056 I Plug (1/2")
516-0141 2

402-0290 4 Bushing, Spacer - Vibration

CUSHION,
402-0285
402-0287
402-0282
526-0014

WASHER

526-0198

405-1403
405-1265
505-0449

505-0027
502-0153

123-1061

850-0045 2
850-0055 10
850-0055 4

800-0026 2
800-0072 10

800-0081 4

QTY.

USED

*Pin,

VIBRATION - CONE SHAPED

2
2
4
4

As Req. 5/8" I.D. x

1 Pan. Drip
2 Clamp, Drip Pan Hold-down

I Nipple, (l/4"x 6") Water

I Coupling (1/4") Water Drain

I Plug (1/4") Water Drain

I Damper, Breather Pulsation -

1 Hose, Overflow — Pulsation

2 Clamp, Overflow Hose -

I Cover, Breather Pulsation

I Pin, Cotter - Filter Retainer

I Gasket, Breather Pulsation

I Hose, Damper Cover to

I Hose, Damper Cover to

4 Nut, Washer Base - Spec A

I Nipple, Oil Drain - Spec A

I Tee, Oil Drain - Spec A

I N ipple, Half - Damper Hose

Mount

Engine End
Generator End
Snubber, Shock Mounting

Washer (29/64" I.D. x

O.D. x 1/8")

1/16"

Drain

Spec A through B

Damper - Spec A through B

Spec A through B

Damper - Spec A through B

- Spec A through B

Damper - Spec A through B

Manifold - Spec A through B

Breather Cap - Spec A
through B

through B

through B

through B

to Oi I Drain - Spec A
through B

Clamp, Hose - Spec A through B

Oil Fill Tube Mounting (5/16")
Oil Base Mounting (7/16")
Mounting Cushion (7/16")

Oil Fill Tube Mounting
Oil Base Mounting (7/16-14 x

1-1/4")

Mounting Cushion

PART

DESCRIPTION

Gear Cover Locating

1-1/2"

1-1/2'

O.D. x

33

I

2

3
4
5

105-0274

515-0001

I 50-0075

105-0205
105-0218

Camshaft (Includes Pin)

Key, Camshaft Gear and

Injection Pump Drive Gear

Pin,

Camshaft Center
Washer, Thrust
Gear, Camshaft (Includes

Spacer and Plate)

REF.

NO.

6
7

8
9 147-0142

10 518-0195

PART

NO.'

510-0046 •

150-0775

150-0078

QTY.

USED

10

1 ,
1
1

1

PART

DESCRIPTION

Ball,

Fly - Governor

Cup,

Governor

Ring,

Snap, Center Pin
Gear, Injection Pump Drive
Ring,

Retainer, Injection

Pump Drive Gear

PISTON

REF.

NO.

8 805-0012

AND CONNECTING ROD

PART

NO.

RING SET

I 13-0137

I 13-0 137-05
I 13-0137-10
I 13-0137-20
I 13-0137-30

I 13-0137-40
PISTON & PIN (
I 12-0118

I 12-01 18,05

I 12-01 18-10
112-01 18-20
I 12-01 18-30
112-0118-40

PIN,

PISTON

112-0117

I 12-0085

I 14-0168

BEARING HALF,
1 14-0164 8
114-0164-02 8

1 14-0164-10
1 14-0164-20
1 14-0164-30
114-0170 8

GROUP

QTY.

USED

4

4
4
4
4
4

INCLUDES PIN RETAINING RINGS)

4 Standard

4 .005" Oversize
4 .010" Oversize
4
4 .030" Oversize
4 .040" Oversize

4 Standard
8 Ring, Retaining, Pin
4 Rod Ass-embly, Connecting

8
8
8

Standard

.005"
.010"
.020"
.030"
.040 "Overs ize

.

020" Oversize

CONNECTING ROD

(Forged)

Standard

.002"
.010"
.020"
.030"
Bushing,

Connecting Rod, Semi­fin ished

Bolt, Place, (5/16-24 x

1-13/16")

PART

DESCRIPTION

Oversize
Oversize
Oversize
Oversize

Undersize
Undersize

Undersize

Undersize

Piston Pin

34

CRANKSHAFT

AND

FLYWHEEL

GROUP

REF.

NO. NO.

2
3
4
5

7

8

.

9

10

12

13
14
15
16 1 04-0546

I6A

17

18

19

20

21

1

104-0464
104-0418
104-0416

518-0188

FLYWHEEL

1 04-0555

104-0548

104-0547

104-0423

800-0500

515-0001

850-0055

526-0185
515-0153

104-0444

134-1401

526-0187

104-0543

115-0150
104-0594

801-0054

PART

QTY.

USED

PART

DESCRIPTION

Crankshaft
Gear, Crankshaft
Washer, Gear Retainer
Ring,

Lock

Includes
Includes Pulley & Ring

Flywheel - With Ring Gear

Gear, Ring

Screw (7/16-14 x 5-1/2"),

Key, Crankshaft Gear

Washer, Lock (7/16")

Washer, Flywheel Mounting

Key, Flywheel
Guard,
Hub & Pulley, Flywheel

Hub,

Washer, (Special)

Spacer & Washer Assembly,

Nut (3/8-24)
Cover, Flywheel Guard

Screw (3/8-24

Hub &

Ring Gear

Gear - Units with Heat
Exchanger

- Optional

Less

Flywheel

Flywheel Mounting

Units with Heat Exchanger
or Keel Cooling - Optional

Flywheel

Flywheel

Hub

Used with Heat Exchanger

Flywheel

or

Hub

Flywheel

to F

lywheel

- Hub to

x 2") - Hub to

Keel Cooling

-

-

to

Crankshaft

-

Hub to

Flywheel

- Not

35

"24

36

START-DISCONNECT

*EF.

NO. NO.

1

2
3
4
5

6

7
8

9

.10

.10

13

13

16

16

PART

191-0496

191-0496

309-0134
309-0152

160-1 143
160-0720

160-0721

160-0721

191 -0392
191-0554

865-00 1 1
815-0201

160-071 1

160-0774

160-0774

QTY.

USED

1 Plate, Start-Disconnect 17

1 Switch Assembly, Centrifugal
1 Plunger, Switch
1 Diaphragm, Switch Plunger
1 Spacer, Switch Plate and/or

1 Gasket, Switch Plate and/or

1 Cover, Plate
1 Control Assembly, Start- 23

1 Nut, Wing (10-32)

2 Screw, Round Head with

2 Spring Weight - Included in

1 Plunger, Thrust 36

1 Plunger, Thrust

PLATE

PART
DESCRIPTION

Switch

Bearing Plate

Bearing Plate

Disconnect Switch (Includes
Weight Springs) 29 338-0263

Shakeproof ET (8-32 x 3/8")

- Centrifugal Switch Mounting

Control Assembly

AND

STOP

SOLENOID

REF.

NO. NO.

I7A 160-0806
18

19
20 306-0161
21
22

24

31
32
33
34

35

37

GROUP

PART

160-0773

SOLENOID, STOPPING

307-0628
307-0668
307-0680
306-0162

306-0159

518-0203
306-0158

336-0706

520-0347

862-0001

306-0242
518-0218
306-0193
812-0148

850-0040 2

QTY.

USED

1

1

1
1
1 Key 2

1

1

1
1
1 Bracket, Solenoid

1

1

' 1

1
1

2

1

2

PART

DESCRIPTION

Spring,

Thrust Plunger

Disc,.Thrust Plunger

Key 1 (l2Volt)

Key 1 (l2Volt)
Key 1 (24 Volt)

Retainer, Solenoid Plunger
Spring,

Solenoid Plunger

Plunger, Solenoid

Ring,

Snap - Spring Retaining

Lead,

Solenoid Ground

Harness, Wiring - Switch

Plate to Control

Stud,

Switch Plate Cover
Nut (1/4-20)
Screw, Solenoid Adjusting
Ring,

Retaining
Cover, Solenoid Plunger
Screw (1/4-20 x 1/2' ) -

Solenoid Mounting

Washer (1/4") Lock -

Solenoid Mounting

36

26

24

20

REAR BEARING

PLATE

OIL

SYSTEM

REF.

NO.

I

2

3
4
5

6
7
8
9

10 505-0057
11 502-0037

12 120-0636

13 502-0097
14

15

16 502-0242

17 502-0282

PART

NO.

120-0547
120-0580

120-0601
120-0602
122-0185
122-0188
122-0182
193-0006

502^0053

CONNECTOR,
LUBRICATION

502-0097

502-0274

502-0097

13

16^

22

GROUP

QTY.

USED

I Pump Assembly, Oil
I Gasket Kit, Oil Pump

I

INVERTED MALE - INJECTION PUMP

TEE

I - Spec A Only
1 Begin Spec B (Restricted)

2 Connector, Inverted Male -

I

I

DESCRIPTION

Cup Assembly, Oil Pump Intake

Bracket, Oil Pump Intake Cup
Filter, Oil
Gasket, Oil Adapter

Adapter Assembly, Oil Filter
Gauge, Oil Pressure
Elbow, Street - 45° (I) Oil Gauge

(I)

Low Oi I Pressure Switch

Plug,

Pipe (1/8") Adapter

Elbow, Inverted Male - Oil Line

to Adapter

Line,

Adapter to Injection Pump

Tee

Connector, Inverted Male -

Injection Pump Lubrication Tee

Front Cylinder Head Tee ­Spec A through B

Tee,

Restricted - Injection Pump

Lubrication

Tee,

Restricted - Front Cylinder

Head - Spec A through B

14

PART

12

15

21

/

p=^>

15

28

REF.

NO.

18
19

20
21

22
23
24

25

26

27

28

29

PART

NO.

120-0539
120-0555

505-0274

120-0635
309-0169
502-0053
LINE,

OIL

HEAD TEE

120-0630
120-0697
120-0695

502-0373
CONNECTOR, INVERTED MALE - CYLINDER HEAD

502-0274 I
502-0281 I
502-0281 I

WASHER, LOCK

850-0045 2
850-0045 3

SCREW, HEX CAP
800-0030 2
800-0026 3

QTY.

"

USED

DESCRIPTION

I Valve, Oil By-Pass

I Spring, By-Pass Valve

.1 Plug, Pipe, Countersunk - Oil

I Line, Oil - Rear Cylinder Head

I Switch, Low Oil Pressure

I Elbow, Street - 45° - Cylinder

I Spec A through B
1 Begin Spec C

2 Line, Oil - Cylinder Head -

I Tee, Inverted Flare

Rear - Spec A Only
Rear - Begin Spec B
Front - Begin Spec C

Oil Pump Mounting
Oil Filter Adapter Mounting

Oil Pump Mounting
Oil Filter Adapter Mounting

PART

By-Pass

- Spec A through B

Cut-Off

Head Tee - Spec A through B

Begin Spec C

23

17

37

34 35

4^ 2C 2 y^''6'^

GEAR

WATER

REF.

NO.

1 103-0267

2 ' 150-0838

2B 150-1095

2C 815-0176
3 516-0117

4
5

6

7
8

9
10
I I
12
13
14

15
16

17
18

19

27 502-0247

PART

NO.

150-0777

518-0129

509-

0088

510-

0048
510-0082
510-0043
509-0087

103-0251
103-0218
103-0228
PUMP,
13

1-0152

132-01 15

131-0127

502-0076

130-0628
130-051 I

502-0074

WATER

COVER^GROUP

PUMP

QTY.

USED

GROUP

PART

DESCRIPTION

Cover Assembly, Gear

(Includes Parts Marked *)

•Shaft, Governor
Arm,

Governor

•Screw (#8-32 x 12")

•Pin,

Roll - Governor Cup

Stop

•Yoke,

Governor

•Ring,

Yoke Retaining

•Seal,

Governor Shaft

•Bearing,

•Bearing,

•Ball,

•Seal
Gasket, Gear Cover
Gasket, Backplate

Backplate

tUnits Without Heat Exchanger
tUnits With Heat Exchanger

Gasket, Water Pump Mounting
Elbow, Inverted Male - Water

Line,
Clamp, Water Line
Elbow, Inverted Male - Water

Tee,

I /2 " Shaft
1/4" Shaft

Governor Shaft Thrust

Pump Outlet

Water - Pump to Block

Line to Block

Male - Cylinder Block

Water Inlet - Rear

AND

27 28 29

REF.

PART

NO. NO.

28 130-0533 I Adapter, Hose
29 502-0239 I Nut, Inverted - Hose Adapter

QTY.

USED

PART

DESCRIPTION

32

to Tee

Hose,

30 503-0394

503-0183 2 Clamp, Hose

31

502-0237 I Elbow, Cylinder Block Inlet

32

502-0304

33

WASHER, LOCK

34

850-0040 2

850-0045 5

850-0045 I
850-0025 I
SCREW, HEX CAP

35

800-0006

800-0028

I 10-0879

800-002.6

815-0347

36 526-0115

• - Contained in Gear Cover Assembly,

t - See Separate Group for Components.

1 Elbow, Water Pump Inlet

2 Water Pump Mounting

I Gear Cover Mounting

4 Gear Cover Mounting

1 Gear Cover Backplate Mounting

2 Screw (1/4-20 x

5 Washer (5/16") - Gear Cover

Water - 9"- Front to

Rear Cylinder

- Front

Water Pump Mounting
Gear Cover Mounting
Gear Cover Backplate Mounting

•Governor Arm Mounting (#8)

(5/16-18 x I ")

(5/16-18 x

Cover Backplate Mounting

Mounting

1-1/4'

1/2")-

)

Gear

3&

AIR CLEANER AND FUEL FILTERS

GROUP

45

1 1

^9

8

0-27

o

, o o « 1

©-28

-26

•25

IO

30

14

12

29

39

o

T

16

REF.

PART

NO. NO.

140-0584 I Gasket, Air Cleaner

2

505-0 180 I Plug, Pipe, 1/4", Intake

3

154-0733 2 Gasket, Intake Manifold

6

140-0706 I Gasket, Manifold Heater

8

140-0705 I Plate, Manifold Heater Mtg.

9

508-0103 2 Sleeve, Insulator Manifold

10

114-0023 2 Screw (1/4-20 x

I I

123-1 I 16 I Tube, Nylon, Breather Hose to

12

508-0102 2 Washer, Insulator Mica -

14

16

332-0829 I Strap, Jumper, Air Heater

17

520-0011 4 Stud - Intake Manifold Mounting

18

870-0048 4 Nut (5/16-18) - Intake Manifold

19

336-133 1 I Lead, Air Heater to Solenoid

MANIFOLD, INTAKE

21

154-1376 I
154-1379 I

LEAD.

23

336-1505 2 #2 & #3 Cylinder (5-1/4")
336-1504 2 #1 & #4 Cylinder (12-1/4")
HEATER, MANIFOLD, INCLUDES GASKET (I2VOLT)

24

154-0712 2 Key I

154-0712 3 Key 2

25

149-0428 I Cartridge, Secondary Fuel

26

149-0456 I Gasket, Secondary Filter,

27 149-0455 I Gasket, Secondary F i Iter,

28 149-0493 I Gasket, Secondary F ilter,

29

149-0769 I Plug, Air Bleed, Secondary

30

502-0041 2 Elbow, Inverted Male,

QTY.

USED

GLOW PLUG TO AIR HEATER

PART

DESCRIPTION

Manifold

Insulator

Heater Mounting

Manifold Heater Mounting

Manifold - Spec A through B

Manifold Heater Mount ing

Mounting

in Control

Key I
Key 2

Filter - Spec A Only

Bowl to Cover ­Spec A Only

Cartridge to Head -

Spec A Only

Cartridge to Retainer -

Spec A On ly

Filter - Spec A Only

Secondary Filter Inlet &
Outlet - Spec A Only

1-1/4")

REF.

NO.

31

32

33

34 526-0068

35

36 526-0066

37 801-0053

38

39

40

41

42

43
44
45

46

47 800-0026

49 501 -0007 2
50

51

PART

NO.

149-0408

LINE,

FUEL PUMP TO SECONDARY FILTER
149-0806
149-1 189

502-0003

801-0074

LINE,

FUEL

PUMP

501-0091

501-

0129

502-

0099

122-0325

122-0326

149-1 185

140-0803
502-0080
517-0104 1

850-0045

800-0012

850-0040

SECONDARY FILTER TO INJECTION

QTY.

USED

1

1 Spec A Only
1

1

1

1

1

1

I

1

1

1

1

2

3

3

2

DESCRIPTION

Filter, Secondary Fuel, (Includes

Cartridge) - NOTE: Bleed Plug

149-0769 is Available

Separately - Spec A Only.

Begin Spec B

Connector, Primary Fuel

Filter Inlet - Begin Spec B

Washer, Primary Fuel Filter

Mounting - Begin Spec B

Screw, Hex Cap - Primary Fuel

Filter Mounting - Begin Spec B

Washer, Secondary Fuel Filter

Mounting - Begin Spec B

Screw, Hex Cap - Secondary

Fuel Filter Mounting -

Begin Spec B

Spec A Only
Begin Spec B

Elbow, Reducer - Secondary

Fuel Filter Outlet - Begin

Spec B

Filter, Fuel - Primary -

Begin Spec B

Filter, Fuel - Secondary -

Begin Spec B

Adapter, Fuel Filters -

Begin Spec B
Resonator - Begin Spec C
Plug,

Filter Drain

Plug,

Core Hole (Intake

Manifold)

Washer, Lock - Fuel Filter

Adapter Mounting

Screw, Hex Cap - Fuel

Filter AdapterMounting

Line,

Flexible - Fuel (24")

Screw (1/4-20 x 2-1/4") -

Resonator Mounting

Washer (1/4") Lock -

Resonator Mounting

PART

40

FUEL

TRANSFER

2

3,7-

PUMP AND INJECTION

SYSTEM

©ROUP

fl

6 f

33

41

20

30

29.

tJ

REF.

NO.

1

2

3

4

5

6

6

7
8

9
10
1

1

12
13 502-0002

14
15 502-0245
16

17

18 149-1062 1

19

20

PART

NO.

149-1046

862-0015

147-0043 4

147-0134

f 10-0419 4

147-0044 8

502-0065

502-0002

147-0243 4 Gasket, Nozzle
I47-OI4I

147-0136 4 Nozzle & Holder Assembly

1

49-0463

149-0792

149-0517

526-0065

LINE,

INJECTION PUMP TO NOZZLE, INCLUDES

FITTING

149-1150
149-1 151
149-1 152
149-1 153

LINE,

NOZZLE FUEL RETURN
149-1060 1 #1 Cylinder (19-1/8 )
149-1059
149-1061 1 #4 Cylinder (19-5/16")

WASHER, FLAT
526-OI22
526-0022
850-0045

QTY.

USED

1

Repair Kit, Fuel Pump (Includes

4

4

2

2

4 Flange, Injection Nozzle

1

1 Gasket, Fuel Transfer Pump

1 Gasket, Fuel Pump Bowl

2

2

1

1
1
1 #3 Cylinder
1

2

4
4 Injection Pump Mounting
4

Diaphragm & Gaskets)

Nut, Injection Pump Mounting

(5/16-18)

Gasket, Nozzle Heat Shield

(Asbestos)

Nozzle Only, Component of

Nozzle & Holder Assembly

Gasket, Shield to Head

(Copper)
Shield,
Elbow, Inverted, 45°, Nozzle

(Fuel Return Line)

Elbow, Street - Nozzle (Fuel

Return Line) - 90°

Holddown

Screen,

Mounting

Elbow, Fuel Pump - Inlet

and Outlet
Washer, Fuel Pump Mounting
Adapter, Return Lines

#1 Cylinder
#2 Cylinder

#4 Cylinder

#2 & #3 Cyl inders (12-3/8")

Line,

Fuel Retainer Lines Adapter

Nozzle & Holder Mounting

Lockwashers, Injection Pump

Mounting (5/16")

PART

DESCRIPTION

Nozzle Heat (Steel)

Fuel Pump Filter

Injection Pump to

REF.

NO.

21­22
23
24
25

26 BUTTON, INJECTION PUMP PLUNGER

27
28

29
30

31 147-0145 1

32 SCREW,HEX

33

34

35 800-0027 2

PART

NO.

147-0183

147-0232
149-1038
I 49-0662

ELBOW, INJECT
502-0054
502-0039

USED

147-0147
147-0148
147-0149
147-0

150
147-0151
147-0161

147-0152
147-0153
147-0154
147-0155
147-0156
147-0190
147-0189

.

147-01

88
147-0187
147-0186

520-0129
509-0094

147-0182
147-0196

1 14-0022

800-0027 2

526-0122

526-0065

CAP

QTY.

ON

!

8

8

2

PART

DESCRIPTION

Valve,

Bleeder, Injection Pump
Pump, Fuel Injection
Pump, Fuel Transfer
Bowl,

PUMP INLET

Fuel Pump (Metal)

Spec A Only

Begin Spec B

.1 19 - Marked I or A

.1 16 - Marked 2 or B
.113 - Marked 3 or C
.1 10 - Marked 4 or D
. 107 - Marked 5 or E
. 104 - Standard Marked I I or

No Mark
.101 - Marked 6 or F
.098 - Marked 7 or H
.095 - Marked 8 or J
.092 - Marked 9 or K
.089 - Marked 10 or L
.122 - Marked 12 or M
.125 - Marked I 3 or N
.128 - Marked 14 or P
.131 - Marked I 5 or R
.134 - Marked 16 or S

Stud,

Injection Pump Mounting

Seat, O-Ring, Injection Pump

to Crankcase
Tappet, Injection Pump
Gasket, O-Ring, Injection

Pump Tappet

Shim Kit, Injection Pump

Mounting

Nozzle & Holder Mounting

(5/16-18 x 2-3/4")

Transfer Pump Mounting

(5/16-18 x 7/8")

Washer, Flat - Nozzle &

Holder Mounting

Washer (Copper) - Fuel

Pump Mounting

Screw (5/16-18 x 7/8") -

Fuel Pump Mounting

tail

<m

GOVERNOR GROUP

REF.

NO. NO.

1
2 150-1082
3

4

5
6

7
8

10

1

1

* - Included in Governor Linkage Assembly.

PART

150-1084

862-0003

150-1103

150-0823
150-1132

150-1358
870-0188
870-0133

870-013 1

QTY. PART

USED

DESCRIPTION

Spring,

Governor

Stud,

Governor Adjusting
Nut, Governor Adjusting Stud
Bracket, Governor Spring

Cover, Governor Spring

Linkage Assembly, Governor

2 'Joint, Ball
2 *Nut, Governor Linkage

1 Palnut, Governor Adjusting

2 *Nut with Shakeproof ET (10-32)

(Includes Parts. Marked *)

Lock

42

WATER PUMP PARTS GROUP (131-0152)

NOTE:

This pump used on sets without heat exchanger only.

REF.

PART

NO. NO.

131-0I52 I Pump, Water
I3I-0I79 I Kit. Repair (Includes Parts

I3I-0I54 I Bearing & Shaft Assembly
I3I-0I57 I •Seal Assembly

518-0221 I •Retaining Ring

I3I-0I58 I 'Wear Plate, Rear
I3I-OI59 I *Cam

QTY.

USED

I Body (Not Sold Separately)

PART

DESCRIPTION

Marked •)

REF.

NO. NO.

7

8 I3I-0I60 I •Impeller
9 I3I-0I6I I •Gasket, Cover

IO I3I-0I62 I •Cover

II 502-0080

• - Included in the I3I-0I79 Repair Kit.

PART

815-0283

QTY.

USED

4 Screw, Brass (I) *Cam

2

DESCRIPTION

Mounting (3) Cover Mounting

Plug,

Pipe

PART

1 •MOTOR STARTER (See Separate Group for Components)

I9I-0324 I Key I (l2Volt)

I9I-0443 I Key2(24Volt)
2 I9I-05I2 I Flange. Starter
3 I9I-03II I Spacer, Starter Flange
4 I9I-0365 I Bracket, Starter Support
6 338-0265 I Harness Assembly - Starter to

Control

7 CABLE, BATTERY (SELECT BY LENGTH)

4 16-002 I 2 20-1n" Long
4I6-0077 2 28-l/4"Long

4I6-O004 I Cable, Battery Jumper

CLUTCH,STARTER

I9I-0432 I For l2Volt

I9I-0432 I For 24Volt

WASHER, LOCK (3/8")

850-0050 2
850-0050 3
SCREW, HEX CAP

10

800-0051 2

800-0054 3

• - See Separate Group for Component Parts.

Starter Motor Mounting
Starter Flange Mounting

Starter Motor Mounting

(3/8-I6 x

Starter Flange Mounting.

(3/8-I6 x 2")

43

I-I/4")

WATER

PUMP

PARTS

GROUP

(132-0074)

NOTE:

This pump used in units with keel cooling only.

WATER

PUMP

PARTS

GROUP

(132-0110)

REF.

NO.

2
3

4

5
6
7
8

9
IO
I

I
12 I32-0I40
13 132-0139
14

PART

NO.

132-0074
I32-0093

I

132-0143
132-0144
I32-0I45
I32-0087
J32-0088

810-0099

132-0089

I32-OIOI

132-0091
I 32-0092
I32-0I38

132-0132

-

Included in the 132-0093 Repair Kit.

QTY.

USED

I
I

•

I

I

Pump, Water - Complete

Repair

'

I
I

I

I

I

I
I
I
I
I

Marked

Pedestal
Body, Pump
Cover, Pump

Impeller

•Gasket, Cover

•Screw (#10-24 x 7/16"), Brass

•Shaft

•Seal,

•Ring,

•Cap,
Screw,

Nut
Lockwasher

Ring,

PART

DESCRIPTION

Kit

(Includes Parts

•)

and

Bearing Assembly

Mechanical

Seal Wear

Wear Ring

Cap

Snap

NOTE:

This pump used on units with heat exchanger only.

REF.

NO. NO.

I
2 132-0137
3 132-01
4
5
6 132-0092
7 132-0112
8
9

10 132-0139
I

I

.12

13
14
15

* - Included

PART

132-01

10

132-011

132-0136

14

132-0101

132-0091

132-01

13

132-0138

132-0140
132-0141
132-0142
132-0089
132-0132

in the

1

QTY.

USED

'

|

1

1
1
1
1

1
1
1

1
1

1
I

1

1

1

132-01 1 1

PART

DESCRIPTION

Pump, Water - Complete
Repair

Kit

Marked

Body, Pump

Cover, Pump

•Impeller

•Seal

•Face,

•Seat, Seal

•Gasket, Cover

•Screw, Cover
Screw,
Lockwasher
Nut,
Plug,
Pedestal

•Shaft
Ring,

Repair

(Includes Parts

*)

Wear

Cap

Hex

Drain

and

Bearing Assembly

Snap

Kit.

14 13 15 4

A/

1

9

44

WATER

PUMP

PARTS

GROUP

(132-0115)

NOTE:

This pump used on units with heat exchanger only.

REF.

NO. NO.

1
2
3
4 132-0121
5 515-0002
6 132-0122

7
8
9 132-01 17

10

t 1 132-0118

12
13
14 132-0128
15
16

17

• - Included in the 132-01 16 Repair Kit.

PART

132-0115
132-01 16

800-1003

132-01 19
132-0120

132-0123
132-0124

132-0125

132-0126
132-0127

850-1040

132-0129
132-0130

QTY.

USED

1

'

1
1
1

1
1
I
1
1
1

I

1

I

1

1
1
1

PART

DESCRIPTION

Pump, Water - Complete

Kit, Repair (Includes Parts

Marked *)

Screw, Cap

Ring,

Retainer - Seat & Seal

•Bearing,
Slinger

Key

Ring,

•Bushing ­Screw, Cam

•Impeller -

Cam

•Gasket, Cover -

•Seat .

•Seal

Shaft'

Lockwasher, Cover Mounting
Cover (Includes Bushing)
Seal and Seat Package

Ball —

Retainer - Drive End

45

REF.

NO.

6
7
8
9

10

I

I

12
13

14

15

16

PART

NO.

MOTOR,STARTER

191-0324
191-0443

ARMATURE

191-0712
191-0713
191-0432
191-1023

COIL PACKAGE, FIELD

191-1024
191-1043

PLATE ASSEMBLY,

191-1025
191-1042
191-1020
191-1026
191 -0497
191-1027

191-1028

SWITCH,

191-0433
191-0715
191-1029
191-1030

191-1031

BRUSH

I9J-0434
191-0774
191-1032

I

I
I
I
I

I
I
I
SOLENOID
I
I
I
I

SET,

I
I 24
I

QTY.

USED

12

Volt

24

Volt

I
I 24Volt
I Clutch
I Head Assembly, Commutator

I

l2Volt

End

l2Volt

24Volt

BRUSH

l2Volt
24 Volt
Spring
Connector Package
Bearing (Bronze), Drive
Spring,

Core Assembly, Moving

PART

DESCRIPTION

Set,

Brush

(Set of 4)

Plunger

l2Volt

24Volt

Yoke Parts Package
Stop

and

Lock Ring Package,

Pinion

Thrust Washer Package,

I

SERVICE

l2Volt

Yoke

Armature

Volt

(Use as

End

Required)

46

MANIFOLD AND

NOTE:

Some parts illustrated are not used or differ on sets

with Heat Exchanger or Keel Cooling. See also these
separate groups.

REF.

NO.

1 1 54-0723

5

6

7

8

9 502-0103

10

1 1

12
13

14

15

16

17

19

20

21

PART

NO.

154-1057

505-01 10

502-0074

130-0510

COVER,THERMOSTAT
309-0160

309-0161
505-0274

309-0145
309-0130 2
520-0143
309-OI56

309-0154

869-0002

PLUG,

EXPANSION

517-0041

517-0059 1

502^0237

503-0586

THERMOSTAT

QTY.

USED

1

4

1

2

2

2

2

2

2

2

4

1

1

4

4

1

1

DESCRIPTION

Manifold,

Cooled

Gasket, Exhaust Manifold to

Head

Plug (3/8"), Manifold Water

Drain

Elbow, Inverted Male - Manifold

Water Line Inlet

Line,

Water - Thermostat Cover

to Manifold

Connector, Inverted Male -

Thermostat Cover Outlet

Sets Without Keel Cooling
Sets With Keel Cooling

Plug (1 /8 " - Countersunk) -

Thermostat Cover
Gasket, Thermostat Cover
Thermostat Models
Stud,

Thermostat Cover

Switch,

High Temperature

Cut-off

Cover, Thermostat Switch -

Sets With Switch Mounted

Nut, Acorn (5/16-24) - Thermostat

Cover Stud

Brass - 1 - 1/8" Diameter
Brass -

1-7/16"

Elbow, Brass - Exhaust Manifold

Water Outlet

Hose,

Rubber (1/2 x 36") -

Water Outlet & Inlet

GROUP

PART

Exhaust, Water

Diameter

REF.

NO.

22
23

24
25
26

27

28 505-0494

29 505-0489

30

31

32

33

34 526-0022

35

36

PART

NO.

503-0446
502-0080

TEE,
WATER LINE)
505-0486

155-1059
154-0894

505-0194

503-0576

502-0237

503-0465
505-0402

110-0445

526-0045

1

55-0640

QTY.

PART

USED

DESCRIPTION

2 Clamp, Water Hose

1 Plug (1/8" - Square Head Brass)

REDUCING - EXHAUST (WITH PROVISION FOR

1 Early Models
1 Late Models
1 Tube Assembly, Water Hose

1 Nipple, Close (1-1/2") - Exhaust

1 Elbow. Pipe (l-l/2"x 90°) -

1 Plug, Exhaust Manifold End

1 Elbow, Exhaust Hose - Late

1 Elbow, Brass - Water Hose

2 Clamp, Hose - Exhaust Elbow

1 Plug (1-1/2") - Exhaust

4 Washer, Flat (5/16") -on Cover

4 Washer, Flat (5/16") -

8 Nut, Hex (5/16-24) - Manifold

8 Washer, Flat (5/16") -

1 Muffler (Elasto Muffler) -

- Manifold End Cap - (Used on
some early models)

Adapter - Early Models

(Early Models used Qty. of 2)

Exhaust - Early Models

(1-1/2 x 1/8") - (Used on

some early models)

Adapter - Late Models

Manifold End - Begin Spec D

Manifold End - Begin Spec D

Thermostat Cover Stud

Mounting

Manifold Mounting

Neoprene Rubber - For

Wet Exhaust - Optional

47

45^

"fe^

46-^i, N

44

7

^

48

^

•»

i

Kg

32

HEAT EXCHANGER QROUP (OPTIONAL) -

SPEC A THROUGH C

REF.

NO.

I

2

4
5

6

7

8

9
10
I I

12

13

14
15
ISA

16
17
18
19

20

21 503-0217

PART

NO.

I 30-0624
130-0575

502-0103 .

130-0746

502-0080

130-0589

130-0590
130-

0519

502-01

55
309-0145
309-0156

502-

0258

CLAMP, HOSE

503-

0183

503-0446

502-0263
502-0085

132-01

10

131-

0130
51 I -0067
512-0042
130-0591

130-0692

QTY. PART

USED DESCRIPTION

I Exchanger, Heat
I Line, Water - Expansion Tank

I Connector, Inverted Male -

I Tank, Expansion
I Plug, Expansion Tank Fill Vent
I Cap, Pressure
I Neck & Adapter, Expansion Tank

1 Gasket, Neck & Adapter

3 . Plug. (3/8")

2 Gasket, Thermostat Chamber

1 Switch. Hi-Temp. Cut-Off

6 Nipple (3/8" x 2"), Half-Hose

8

1-1/16"
2 25/32"
3 Elbow (90°-3/8")
6 Nipple (3/8") , Close Brass

I 'Pump, Centrifugal Water - Less

to Exhaust Manifold

Expansion Tank Outlet

Cap

Connection

Pulley

Bar, Pump Hold-down

Belt, Centrifugal Water Pump
Pulley, Centrifugal Water Pump

Guard,

Belt

Bracket, Heat Exchanger &

Governor Spring

Hose,

Rubber (3/4" I.D. x 56"

- Total length required for all
hoses-except raw water pump)

48

REF.

21

21
21

22
23
24
25

27
28

29
30

31
32

33
34
35

36

37

PART

NO.

503-0285

503-0478

503-0461

502-0257

130-0892

503-0679

821-0005

505-0266

502-0074

502-0298

800-0005

850-0040

130-0626

502-0049
504-0006
502-0300

502-0302

502-0237

* - See Separate Group for Components.

QTY.

USED

1

1
1

2

1
1

6

1

1

1

2
2

2

1

1

2

1

1

Hose,

Raw Water Pump to Heat

Exchanger - Begin Spec B

Hose (3/4" I.D. x 9") - Cylinders

#1 & #2 to Cylinder #3 & #4

Hose,

Raw Water Pump to Heat

Exchanger - Spec A Only

Tee (3/8 7')

Stiffener, Filler Neck
Hose (13"), Overflow
Screw, Locking (10-32 x 1/2") -

Neck & Adapter Mounting

Plug (3/8"), Exhaust Manifold

Elbow, Inverted Male - Manifold

Water Line Inlet •

Elbow, 45° x 3/8"

Screw (1/4-20 x 3/4") - Water

Pump Mounting

Washer (1/4"). Lock

Pencil,

Exchanger)

Bushing,

Valve,

Elbow, Heat Exchanger Fresh

Water Hoses

Elbow, Heat Exchanger Raw

Water Outlet Hose - Begin

Spec B

Elbow, Heat Exchanger Raw

Water Inlet Hose - Begin

Spec B

PART

DESCRIPTION

Rubber (1/2" I.D. x 14") -

Rubber (3/4" I.D. x 12-3/4")

Zinc (Included in Heat

Reducer (3/8" x 1/8")

Air Bleed - Manifold Outlet

REF.

NO.
38

39

40
41

42

43 502-0278

44 502-0237

45 502-0370

PART

NO.

104-0546

309-0238

130-0747

GASKET, HEAT EXCHANGER BONNET

130-0729

130-0730

BONNET, HEAT EXCHANGER

130-0731
130-0732

QTY.

PART

USED

DESCRIPTION

1 Pulley, Flywheel

1 Thermostat - Mounts Inside

1 Plate, Thermostat Retainer

1 Fresh Water End
1 Raw Water End

1 Fresh Water End

1 Raw Water End

2 Elbow, Pump Inlet & Outlet

1 Elbow, Raw Water Pump Outlet

1 Adapter, Hose- Raw Water Pump

Expansion Chamber

Spec A Only

- Begin Spec B

Inlet - Begin Spec B

REF.

NO. NO.

46

47

48

49

NOTE

PART

502-0372

502-0263 2

502-0258 2

502-0085

: For Raw Water Pump,

Group.

QTY.

USED

1

2

PART

DESCRIPTION

Bushing,

Elbow (3/8-90°) - Heat Exchanger

Nipple, Half (3/8 x 2"). Heat

Nipple (3/8 x Close), Heat

Reducer - Raw Water

Pump Outlet - Begin Spec B

Inlet & Outlet - Spec A Only

Exchanger Inlet & Outlet -

Spec A Only

Exchanger Inlet & Outlet ­Spec A Only

49

HEAT EXCHANGER GROUP- OPTIONAL EQUIPMENT BEGIN SPEC D

45

,38

15 A O^J^ ,

12

29

28

23

)

13

2 1

46

13-^

44

39

50

REF.

PART

NO.

NO.

1 130-0911

2 130-0910

3 131-0196

4 504-0006
5 131-0140

6 131-0197
7 502-0300
8 800-0030

9 526-0065

10 309-0145
11 309-0156
12 502-0258

13 503-0183
14 502-0263
15 502-0085
ISA 132-0110

16 131-0130

17 511 -0067

18 512-0042
19 130-0591

20 130-0692

21 HOSE, WATER

503-0495

503-0564

503-0187
503-0564

I

I

I
I

QTY. PART

USED

DESCRIPTION

1 Exchanger, Heat

2 Bracket, Heat Exchanger

2

2

4

As

Req

3
5

I

I

Manifold,
Valve,
Gasket, Water Manifold Outlet
Housing,
Elbow, Hose

Screw (5/16-18 x 1-1/4")

Washer (5/16"), Copper
Gasket, Water Manifold

Switch,

I

..

Nipple (3/8"x

Clamp (1-1/16")
Elbow
Nipple (3/8"), Close Brass

*Pump, Centrifugal Water

Bar, Pump Hold-down

Belt, Centrifugal Water Pump

Pulley, Centrifugal Water Pump

Guard,

Bracket, Heat Exchanger

Governor Spring

Hose (1/2")

Hose (3/4") - Heat Exchanger

to Water Pump
Hose (1/2")
Hose (3/4") - Exhaust

Manifold

Water

Drain

Thermostat

'

Water Pump Mounting

Hi-Temp. Cut-Off

Connection

(90° - 3/8")

Less Pulley

Belt

Discharge

2")

- Sea

- Sea

to

Heat Exchanger

Mtg.

Hose

-

and

Water

Water Inlet

REF.

PART

NO.

NO.

503-0478
503-0472
503-0699

22

-

23
24
25

26

27

502-0257

130-0589

503-0679

800-0005
850-0040

505-0266
28 503-0612
29

502-0298

30

505-0135

31

505-0039

32 505-0277

33

505-0101

34

505-0120
38 104-0546
39 309-0238

44

502-0237

45 502-0370

46 502-0372

130-0915

NOTE:

For Raw

*

- For

Component Parts, Refer

Group.

QTY.

USED

1

•

1

1

1
1
1

2

2

1

2

1
2
3

1

2

1
1
1

1

1

1
1

Water Pump,

PART

DESCRIPTION

Hose (3/4") - Cylinders

to Cylinders

Hose (3/4") - Water Pump

Outlet

Hose (3/4") - Water Manifold

to Exhaust Manifold

Tee

(3/8")

Cap,

Pressure

Hose (13"), Overflow

Screw (1/4-20

Pump Mounting

Washer (1/4"), Lock

Plug (3/8"), Exhaust Manifold
Clamp, Heat Exchanger Mounting
Elbow

(45° x 3/8")
Nipple, Half
Elbow

(3/8 x 90°)
Nipple, Close
Nipple, Close
Elbow, Street
Pulley, Flywheel

Thermostat - Mounted

Manifold #131-0196

Elbow,

Raw

Adapter, Hose

Pumo Inlet
Bushing,

Pump Outlet

Conversion

(Includes
hdwe.

See

etc. for

Gear Cover

to

Separate Group.

#3 & 4

to

Block

x 3/4") -

(3/8 x

(3/8 x

(3/8 x I ")

(3/8 x 90°)

Water Pump Outlet

- Raw

Reducer

- Raw

•

Kit,

Heat Exchanger

all

necessary parts,

field installation)

and

#1 & 2

Water

1-1/2")

1-1/2")

in

Water

Water

Water

Water Pump

51

3

2

IO

1 1

GENERATOR
(REVOLVING

REF.

NO.

1 23 1-01 12
2
3

4

5

6
7 232-0596
8
9

10 520-0640
1

1

12
13

14
15
16 RESISTOR,

17
18
19

20

PART

NO.

205-0064

515-0006

234-0162

*

510-0047

*

21 1-0 146 •

520-0615
212-1064
214-0059

2 12-0280

234-0163

870-0177

304-0500 1 Key 1

304-0534

232-1565

304-0006

520-0620

866-0001

GROUP-

FIELD

QTY.

USED DESCRIPTION

TAPPED ADJUSTABLE

ALTERNATOR

TYPE)

PART

1 Adapter, Engine to Generator
1 Blower, Generator
1 Key , Blower
1 Baffle, Generator Air

1 Rotor Assembly, Wound (Includes

1 Bearing, Rotor
1 Clip, Bearing, Stop
1 Stator Assembly, Wound
1

Bell,

4 Stud, Generator Through

1 Stud, Rotor Through
2 Block, Collector Ring Brush
4 Brush, Collector Ring 29

1 Rig Assembly, Brush (Includes

1 Cover, Air Outlet

1 Clip, Air Outlet Cover

1 Key 2

1 Bracket, Resistor Mounting

2 Washer, Resistor Centering

1 Stud, Resistor Mounting
1 Nut, Res istor Mounting

1 Nut, Res istor Mounting

Bearing & Blower)

End - Alternator to Exciter

Leads, Col lector R ing
Brushes (4) and Blocks

(2)

and Hdwe.) - Not Shown

PORTION

REF.

NO.

21
22

23

25
26

27

28

30
31

33

34
35

36

36
37

38
39
40

PART

NO.

870-0203
232-0200

GROMMET, RUBBER
508-0095 I

508-0112 I
204-0061 I
850-0040 4

SCREW, HEX CAP - GENERATOR ADAPTER MTG.

800-0051
800-0050
850-0055
862-0015

850-0045
516-0083

813-0098

.>

850-0030

812-

0102

150-0956

I 50-0958

868-0004
850-0030
813-

0100

QTY.

USED

I
I

2
2

I

4

4

2

5

I

I
I

I
2
2

PART

DESCRIPTION

Nut, Rotor through Stud

Washer, Tapered - Rotor throu^i

Stud

Air Baffle

Lead Outlet

Collector Ring

Washer, Lock - Generator

Adapter Mounting

3/8-16 x 1-1/4"
3/8-16

x I "

Washer, Lock (7/16")

Nut, Hex (5/16-18) -

Generator Through Stud

Washer, Lock (5/16")

Pin,

Roll (3/l6"x 5/8") -

Al ignment

Screw (10-32 x 3/8") -

Baffle Mounting
Washer, Lock (#10)
Screw, Round Head - Air

Outlet Cover Mounting

Switch Assembly, Overspeed

Bracket & Point Assembly,

Overspeed

Nut, Jam (7/16-20)

Washer. Lock (#10)
Screw (10-32 x 1/2")

52

- Order by Description, giving Model, Spec and Serial
Number.

REF.

NO.

1 301-1962
2 301-1963
3

4 301-1968
6
8

9

12
13
14 302-0446
15

16
18

21
22 332-0706

23

24

25

PART

NO.

PANEL, CONTROL BOX
301-!%!
301-2376 1

307-0597

RELAY, MANIFOLD HEATER AND START SOLENOID
307-1046
307-0061
307-0623
308-0154
308-0037

RECTIFIER, CHARGE
305-0235

305-0238
305-0254
RESISTOR
304-0032

304-0247
332-0604

332-07 50

332-0616

332-0739

QTY.

USED

1 Box, Control

Cover, Control Box

1

1

Standard

Sets with Overspeed

Cut-off Switch

Bracket, Control Box Mtg.

1
1

Relay, Start

2
2

Key 1
Key 2
Relay, Ignition

1

1

Switch,

1

Switch,

1 Ammeter, Charge (5-0-5)

1 Key 1

Key 2

1

Bracket, Rectifier - Key 1

1

Fixed (15-Ohm, 10Watt) -

1

1
1
1

1

1

1

,

Key 1

Adjustable - Key 2

Block, Terminal -4 Place
Block, Terminal - 8 Place

Marker Strip & Wire Holder Kit,

Battery Polarity (Used on some

early models)

Strip,

Remote Control

Strip,

PART

DESCRIPTION

Start-Stop
Manifold Heater

Marker (B +

Marker (4 through 9)

,.l,

2, 3. H) -

PART

REF.

NO.

RESISTOR, TAPPED ADJUSTABLE (Mounts in

28

Generator Air Outlet)
304-0500 1
304-0534 1

29 332-0052 1

402-0078 4

34

337-0036 1

35

301-2467 1

36
37 301-2466 1

GROMMET, RUBBER

38

508-0001 1
508^0009 1

39 332-0602 1

320-0104 1

40

41 RESISTOR

304-0217 1
30470005 1

42 304-0005 1

353-0007 1

43

44 307-0655 1

49 416-0096 2
50 301-2468 1

508-0117 1

51

QTY.

NO.

USED

Key 1

Key 2
Clip,
Mount, Rubber - Control Box
Strap,

Generator

Box, Output
Cover, Output Box

For
For
Jumper, Heater Solenoid to

Start Solenoid

Switch,'

Low Oil Pressure Cut-Off

Switch

(l-Ohm,

(5-Ohm,
Resistor, Adjusting - Key 2
Resistor (5.5-Ohm. 50Watt) -

Key 2

Relay, Overspeed Latching - '

Optional

Clip,

Bracket, Output Box Mounting

Grommet, Output Box - For 3/8"

Hole

PART

DESCRIPTION

Tinnerman

Ground - Control Box to

l-l/l6"Hole
1-5/16"

Emergency - Units With

10Watt) - Key 1

50Watt) - Key 2

Harness Support

Hole

, 53

-OPPOSITE SIDE

9A

GENERATOR

GROUP-

EXCITER

PORTION

54

GENERATOR

NOTE:

Check your set nameplate for the correct Magneciter number. Select the correct Part Number

column that applies to your set.

Check your set nameplate for the correct Magneciter number. Select the correct

Part Number column that applies to your set.

GROUP - EXCITER

06SXINI B used on 60 Hertz 120/240 Volt, 3 Phase sets.

06SXIN3B used on all 60Hertz sets except l20/240Volt. 3 Phase.
06SX5INIB used on SOHertz 120/240Volt, 3 Phase sets.
06SX5IN3B used on all SOHertz sets except l20/240Volt, 3 Phase.

PORTION

REF.

NO.

2

3
4 2
5 2

6

8

9 2 Rectifier Only, Power Field, Negative

9A

9B

10
1 1

12 1

13
14 1

15
16

17

18

20
21

22
24
25
26

QTY.

USED

Exciter Complete (Less Cover)

1

1 1 Cover, Exciter 234-0185 234-0185 234-0185 234-0185

1

Panel Only, Exciter 234-0 J 88 234-0188

2 Reactor, Gate

Gasket, Gate Reactor Mounting, Outer 232-1553 232-1553 232-1553
Gasket, Gate Reactor Mounting, Inner 232-1551 232-1551 232-1551 232-1551
Retainer, Gate Reactor

2

1

Rectifier Assembly, Resistor and Complete

Rectifier Only, Power Field, Positive

2

1

Rectifier, Field Flash

4

4
2

2

1
1
1 Grommet, Rubber, For 7/8" Hole
1 Resistor, Fixed (250-Ohm, 25Watt)
1
1

Rectifier, Voltage Control
Resistor, Included in Rectifier Assembly

1

(150-Ohm,

Block, Terminal 332-0745 332-0745

1

Strip,

Block Marker

Resistor, Tapped, 500-Ohm (425 Fixed,

75 Adj.)

Washer, Resistor Centering 304-0015 304-0015

Spacer, Resistor Mounting
Reactor, Voltage Control

1

Gasket, Voltage Control Reactor
Stud,

(or Screw), Tapped Resistor Mounting

Clip,

Tinnerman

Switch,

Residual Reset

Washer, Retainer, Voltage Control Reactor

PART

DESCRIPTION

5 Watt)

06SXINIB 06SXIN3B 06SX5INIB

209-0008 209-0010 209-0012 209-0013

234-0188

3 15-0102 315-0102 315-0104 315-0104

232-1552
305-0264 305-0388 305-0264 305-0388
305-0238 • 305-0238

305-0239

305-0240

304-0512

332-0746 332-0925

304-0527 304-0527

232-1474
315-0100

232-1548

520-0641
332-0050
508-0008 508-0008

304-0510 304-0510

308-0175
526-0173

232-1552 232-1552 232-1552

305-0238
305-0239 305-0239 305-0239
305-0239

305-0240 305-0240

304-0512 304-0512

332-0745 332-0745
332-0746 332-0925

304-0527 304-0527

304-0015
232-1474
315-0100

232-1548 232-1548
520-0641 520-0641
332-0050

526-0173

232-1474 232-1474

3 15-0105 315-0105

332-0050 332-0050

508-0008 508-0008

304-0510

308-0175

526-0173 526-0173

06SX5IN3B

234-0188

232-1553

• 305-0238

305-0239
305-0240

304-0512

304-0015

232-1548
520-0641

304-0510

• - Later Models Use Quantity of 3.

55

REF.

NO.

1 • I Panel

2 AMMETER, AC (Check Scale, Select According to

3 VOLTMETER, AC (Check Scale, Select According

4 BREAKER, CIRCUIT (Check Original Part, Select

PART

NO.

Rating)
302-0418 As Req. Scale Reads 0-30
302-0444 " Scale Reads 0-35
302-0419 " Scale Reads 0-50

302-0458 •• Scale Reads 0-80

to Rating)
302-0421 1 Scale Reads 0-300
302-0422 I Scale Reads 0-600

According to Amp. and Voltage, 120/240 Volt is I"

Wide,

480 Volt is
320-0150 As Req. 20 Amp., 480 Volt
320-0151 •• 25 Amp., 480 Volt
320-0019. " 25Amp., l20/240Volt

320-0020 35Amp., 120/240Volt

320-0153 " 40 Amp.. l20/240Volt

QTY.

USED

I-1/2"

PART

D«SCWPTION

Wide)

REF.

NO.

8

9
10
11

* - Order by description, giving complete Model, Spec

PART

NO.

320-0198
320-0052
320-0195
320-0148
308-0012

3030076

METER,FREQUENCY
302-0213 I
302-0234 I
302-0448 I
322-0072 2
322-0004 2
308-0002 I

and Serial Number from nameplate.

QTY.
USED

As Req.

I

PART

DESCRIPTION

45Amp.', l20/240Volt
SOAmp., l20/240Volt
55Amp., l20/240Volt
70Amp., l20/240Volt
Switch,

Voltmeter Selector,

3 Phase Only

Knob,

Selector Switch,

3 Phase Only

60 Hertz
50 Hertz

Plate,

Meter Face
Receptacle, Panel Lights
Bulb,

Panel Light

Switch,

Panel Light

56

MANIFOLD

AND

THERMOSTAT

QROUP

23

SPECIAL

REF.

NO..

1
2
3

4

5

7
9

10

12

13

PART

130-0692
132-0074

131-0144
512-0042
511-0068
502-0250
502-0278
503-0183 4
503-03 15

502-0085 2

PARTS

NO.

FOR

QTY.

USED

1

.
1
1

1
1
1
1

1

KEEL

Bracket, Pump & Governor Spring

*Pump, Water - Less Pulley

Bar, Pump Hold-down
Pulley, Water Pump

Belt, Water Pump Drive
Elbow, Outlet (Brass) Pump
Elbow, Pump Inlet - Brass 21 130-0591

Clamp, Hose
Hose,

Hose and Front to Rear 25 850-0040

Nipple (3/8") Cylinder Block * - See separate g

COOLING

PART

DESCRIPTION

Rubber - Total Length

required for Pump to Block

Cylinder

MODELS-

OPTIONAL EQUIPMENT

REF.

NO.

14
15

16

17

23

24

PART

NO.

502-0257
502-0258

502-0263

502-0085

104-0546

800-0005

QTY.

USED

I

4

PART

DESCRIPTION

Tee.

(3/8") Cylirider Block

Nipple (3/8 x 2") (I) Exhaust

Manifold (3) Block

Elbow (90°- 3/8") (I) Exhaust

Manifold (I) Block
Nipple (3/8") Exhaust Manifold
Guard,

Belt

Pulley, Flywheel

Screw (1/4-20 x 3/4") - Water

Pump Mounting

Washer (1/4"). Lock

57

GENERATOR

END

PANEL

MR

DUCT

-2

14

O

SOUND

REF.

NQ.

1

2

3
4

5

6
7
8

9 405-1513

10 405-1517

1

1 405-1536

12

13

14

15

16

PART

NO.

405-1520
405-1478
405-1523
405-1504
405-1500 1

405-1502
405-1494
405-1515

508-0008

508-007 1

508-01 16

508-01 17

800-0084

SHIELD

QTY.

USED

HOUSING

Molding,

1
1

Plate,

1

Panel,

1

Panel,
Panel,

Includes Inlet Duct

1
1
1

1

1

1

2

2

1

2

4

(Insulated)
Base,
Pan,

Drip

Panel,

(Insulated)
Panel,

Outlet Duct (Insulated)
Panel,
Band,
Grommet, Fuel Inlet and

Return (For 13/16 "Hole)
Grommet, Battery Leads

(For 7/8" Hole)
Grommet, Exhaust (For

2-3/4" Hole)
Grommet, Water Inlet and

Leads (For

Screw, Hex Cap - Set to

Base (7/16-14 x 4-1/2")

GROUP-

PART

DESCRIPTION

Corner (Insulated)

Cover

Top (Insulated)
Back (Insulated)
Generator End -

Mounting (Insulated)

Engine End

Door - Includes Air

Access (Insulated)

Duct Adapter

1-3/8"

OPTIONAL

Hole)

REF.

NO.

17 526-0195

18 808-0053
19 SCREW, ROUND HEAD

20

21 NUT, HEX

22

23
24 140-0645
25
27

28
29 406-0342

30

31 406-0283

32 406-0282
33 406-0285
34 516-0037

PART

NO.

812-

0150

813-

0105

850-0030

862-0004
870-0053
503-0267
503-0691

140-1278

800-0006

406-0343

406-0286

QTY.

USED

4

30

20

1
1

4

1

2

1
1
1 Intake, Air
1 Screw (1/4-20 x 7/8") -

4

2

2
2
2
2
2

PART

DESCRIPTION

Washer, Flat - Set to Base

(7/16")

Screw, Sheet Metal (#14 x 3/4 )

Panels to Base (1/4-20 x 5/8 )

Band Mounting (10-32 x 1 ")

Washer, Lock - Band Mounting

(#10)

Set to Base (7/16-14)
Band Mounting (10-32)

Clamp, Hose

Hose,

Air Inlet

Adapter, Air Cleaner

Air Cleaner Adapter

Latch,

Fold ing

Latch

Washer, Latch

Spring,

Latch

Clip,

Latch

Retainer, Spring

Pin,

Cotter (1/16 x 1/2")

58

SERVICE KITS AND MISCELLANEOUS

NOTE:

For other kits, refer to the group for the part in question.

PART

NO.

98-1807

168-0107

522-0242

522-0253

522-0243

522-0252

525-0216

155-0954

155-1004

QTY.

USED

I

PART

DESCRIPTION

Decal Kit
Gasket Kit , Engine
Overhaul Kit, Engine -

Units Without Heat Exchanger

- Spec A Only

Overhaul Kit, Engine -

Units Without Heat Exchanger

- Begin Spec B

Overhaul Kit, Engine -

Units With Heat Exchanger -

Spec A Only

Overhaul Kit, Engine -

Units With Heat Exchanger ­Begin Spec B

Paint, Touch-up (Pressurized

Can) l6ounce - Marine White
Enamel

Pipe Fitting Kit, Aqualift

Muffler

Muffler, Aqualift Marine

59

SPECIAL

PARTS

FOR

15.0MDJF-3CE/

SECTION

(FORMERLY 1 SMD J F-3 E 3836

WORKBOAT

Parts

not listed in this section, refer to the standard

groups, using

parts

Key no. 1.

MODEL

)

parts

START

DISCONNECT

• 2xriy

30

PLATE

AND

STOP

REF.

PART

NO.

NO.

I 131-0142

SOLENOID

QTY.

USED

I

'tz>

57

GROUP

PART

DESCRIPTION

Plate

Assembly, Start-Disconnect

Switch

©3

INTAKE

REF.

PART

NO.

NO.

30 502-0148

32 501-0098

3 8 501-0097

MANIFOLD

QTY.

USED

2

1

/

1

^"

-J&~--38

AND

Elbow, Male - Secondary Filter

Inlet & Outlet - Spec A Only

Line,

to Secondary Filter - Spec
Only 51 140-0602

Line,

to Injection Pump - Spec A Only

FUEL

PART

DESCRIPTION

Flexible - Transfer Pump 56

Flexible - Secondary Filter

FILTERS

A

3?

GROUP

REF.

NO. NO.

-

54 140-1194

55 1 40-0606

57

52 865-0020

53

140-0607
147-0202

520-0621

60

PART

JC9

QTY.

USED

56

PART

DESCRIPTION

Cover,

Air

1
1

Element,

1

1
2
2

2

Pan,

Lever, Stop - Injection Pump
Washer,
Nut, Wing

Only

Stud,

Cleaner

Air

Air

Air

Cleaner

Cleaner

Air

Cleaner

- Air

Cleaner

Cleaner Cover Mounting

is

-52

-4 5 3

54

CONTROL GROUP

REF.

NO.

3
8

14

52
53

54

PART

NO.

30

1-2409

308-0028
302-0058
332-0254
332-0868
304-0330

QTY.

USED

1

2

1

1

1
1

Panel,
Switch (1) Start (1) Heater
Ammeter, Charge (10-0-10)

Block, Terminal (4 Place) '
Strip,

Resistor, 20-Ohm, lOWatt

PART

DESCRIPTION

Control Box

Block.Marker

HEAT EXCHANGER GROUP

1 1

REF.

NO.

55
56
57
58

. 59

60

REF.

NO.

55

PART QTY.

NO.

308-0155
307-0777

323-0052

307-0778
308-0069

332-0439

PART

NO.

309-0191

58

USED

1

1
1
1

I

1

QTY.
USED

56

59

tn

PART

DESCRIPTION

Switch,

Alarm Test

Relay, Alarm
Socket, Alarm Relay
Spring,

Alarm Relay Hold

Switch,

Hi-Lo Charge

Jumper, Terminal Block

Switch,

Hi-Temp. Cut-Off

- *

PART

DESCRIPTION

57

60

FUEL

TRANSFER

PUMP AND INJECTION

13

SYSTEM GROUP

REF.

NO.

13 502-0020 I Elbow, Street - Fuel Pump

36 502-0138 I Elbow, Male - Fuel Pump

PART

NO.

ELBOW FUEL PUMP OUTLET

QTY.

USED

PART

DESCRIPTION

Outlet - Spec A Only

Outlet - Spec A Only

61

OWNER'S

MARINE

SERVICE

WARRANTY

QUALITY

Your
tion

of

this product.

will

GENERAL

All

Onan marine engine-driven electric generator

and sold
that
and operated under normal conditions, according to the manufacturer's instructions. The text of the Onan
published
boat manufacturer's manual.

1.

Warranty Registration: A Warranty Registration card accompanies

2.

Material Allowances: Onan

3. Labor Allowances: Onan

OF

PRODUCT

Onan Marine Electric Generator set is engineered and designed especially for below-deck installa-

on

pleasure

provide many enjoyable hours of service.

with a full

these

warranty

card must be properly
eration
registration

Distributor
warranty

and his Approved or Registered Dealers for straight labor time when the
mined
the factory's standard time schedule of published
judged
owner.

and commercial craft.

With

proper installation, regular maintenance and periodic repair service, the equipment

WARRANTY

products are free

as covered in this

or license number,

or his Approved and Registered Service Dealers, all genuine Onan parts used in a

repair of

to be defective material or factory workmanship. This labor allowance

reasonable

PRACTICES

oneryear warranty. This warranty is issued

from

appears

in the Onan Operator's Manual

filled

bulletin.

these

products

will

by the factory. Repair

Only

quality material and workmanship is used in the manufacture

sets,

separate

defects in material and workmanship when properly installed, serviced,

out and returned to Onan factory for you to

When requesting warranty repair

purchase

will

allow

allow

which

date, Onan

credit pr furnish free of charge to the Onan Authorized

fail

because

warranty repair credit to the Onan Authorized Distributor

flat

work

other than warranty

generators

only

sent

with

Model

and Serial numbers of the equipment.

of defective material or workmanship.

rate

labor allowances, or, otherwise a time

and controls are manufactured

to the

the product, or is included in the

each

original

Onan Marine Product. This
qualify

work

cause

will

user

and promises

for Warranty consid-

you must provide boat

of failure is

will

be

be charged to the boat

deter-

based

on

4.

Miscellaneous

date

of

purchase,
actual warranty repair at the owner's boat location if such repair
Onan Distributor or his Approved or Registered Dealers, and if the boat is docked
area

normally served by the approved servicing organization.

The owner
and mileage after the
warranty

The Onan Division's General Warranty practice

as start-up

cost of

5. Administration: Warranty of Onan Marine Products is administered through Onan Authorized
tributor
or
the

Onan

fuel,

in whose

Registered Dealers are authorized to make settlement of all customer warranty claims

limits

reserves

Expense

no charge

will

be expected to pay the service organization a regular service fee for travel time

period or thereafter when repair

charges,

oil, normal maintenance adjustments, tune-up adjustments or parts maintenance items.

territory

of the manufacturer's warranty

the

Allowances:

will

first

six(6) months period has elapsed, and, at any time during the one year

communication

the equipment is located.

right

to

change

During

be

made

charges,

warranty practices

the

for travel time or mileage when it is

work

transportation

policy

first

six (6) months

work

is not due to defective material or workmanship.

does

not provide for allowance of

charges,

These

as described herein.

Service Stations and their Approved

without

prior

from

the

original

necessary

is performed by an authorized -

within

expenses

unit

removal or reinstallation,

notice.

owner's

to perform

the

within

local

such

Dis-

MAINTENANCE

A

Planned Preventive Maintenance Program is extremely important if you are to receive

tion

and

long

service

failure

or permanent

the boat manufacturer's manual, contains recommended maintenance

life

from

damage

your Onan

to your equipment. The Onan Operator's Manual

unit.

Neglecting routine maintenance can result in premature

schedules

sent

with

and procedures.

efficient

the product, or

opera-

Maintenance is

1.

Operator Maintenance performed by the operator.

2.

Critical

Regular maintenance

this

scheduled maintenance must be offered when applying for a warranty

INSTALLATION

Installation

the owner experiences any

or

fuel

lines,

so that corrective action can be taken.

Registered Dealers may be able to remedy certain installation

considered Onan warranty and there

MSS-21A
Replaces MS-12
Rev. 11-1-71

divided

Maintenance perfonned

of Onan Marine Products is usually performed by the boat manufacturer or his dealer. If

wiring,

into

two categories: '

only

by

qualified

will

help you

difficulty

etc., he should immediately contact the dealer

avoid

sudden and costly repairs in the future. Adequate evidence of

with

such items as mounting,

Although

will

be a charge for this service.

the Onan Authorized

service personnel.

claim.

ventilation,

from

whom

Distributor

difficulties,

Onan,

such repair

Division

Minneapolis,

exhaust location, water

he purchased the boat

or his Approved and

work

is not

of Onan Corporation

Minnesota 55432

ONAN

1400 73RD

AVENUE

N.E. • MINNEAPOLIS, MINNESOTA 55432

A DIVISION OF ONAN CORPORATION