4.0 CCK rebuild everything project..It needs it!

[RockwoodMike]

This is the Onan 4.0 CCK gen set out of my 1973 D22 Indian..It needs help..So let's help it..

These 4 pics are a look over of it before starting..

[RockwoodMike]

Pics 1-2 some labels..first one is hard to read

Pic 3-4..just removing covers to see what is under them

[RockwoodMike]

Pic 1..points for the ignition..burnt!!

Pic 2..Control center electronics..300C859..there is a company called dinosaur electronics on Ebay that has made a replacement for this if needed..

Pic 3..Front shroud and fan removed..Fan was filled with dust..

Pic 4..Cylinder head removed..Plenty of carbon

[RockwoodMike]

where the valves are adjusted..Must remove exhaust and intake manifolds to get to these access covers..I don't think they have ever been adjusted

[RockwoodMike]

Some more tear down photos..

[RockwoodMike]

More photos..

The armature was a bear to get it to release from the crankshaft..Tapered fit that has been that way for over 50 years

Last photo shows several of the parts laid out, ready to be refurbished..

[RockwoodMike]

Using a 3 arm puller, the front flywheel came off fairly easy..It is on a tapered shaft too..

Showing the parts under the front cover..

I need to order a special valve spring compressor to get into these tight spaces..here is the link to what is on order for me from Ebay..

https://www.ebay.com/itm/131426682516

[RockwoodMike]

Pic 1..Small valve spring compressor..A little too small..It struggled to do the job..

Pic 2..One set of valve..spring..keepers..cam follower..

Pic 3..Compressor in action..

Pic 4..With all the valves out..ready to remove cam..Take off thrust washer from the crank first..

[RockwoodMike]

Cam is out..One rod cap is removed..This has no bearing shells to the rod..Crank looks Great!!

[RockwoodMike]

Got the engine to the machine shop..Going see if it needs to be bored or just honed..Also a quick valve job

Pic 1..Removed all the brushes from the casting..Drew a good diagram where it all goes together..No crossed wires that way

Pic 2..Empty case to be cleaned and painted

[RockwoodMike]

Here is the bell housing piece for the generator..This is the piece that bolts direct to the engine

Before and after a good sand blasting cleaning..

[RockwoodMike]

Pic 1..Got the engine back from the machine shop..Just needed a hone and a touch up valve job..Hot tanked to clean it well..

Pic 2..This is the rubber mounts to replace the original mounts that can't be found new anywhere..They fit a Mercedes diesel application..Just an inch taller..But fit the application good..

Pic 3..After some rework, the shelf that mounts the generator will now be able to slide out about 12 inches to make servicing it easier..

[RANGERRICK]

Along time ago Onan had a kit to replace the control board,not sure if it is still available,If you run into an issue get parts let me know i have some older parts kicking around.
Bill

[RockwoodMike]

Hi Bill,

Yes I have seen talk on the forums about control boards. I searched for a replacement board using the number on the board and there is a company called dinosaur electronics that replicates the board original to it..

The previous owner did start the gen set when I was buying the motorhome..It ran rough and he didn't use it for power to show me..He just started it and then shut it down..

So I don't know if the board I have is good or not..We will see..

Parts for the engine, like a complete engine kit can be found..varying in what parts are included..

I have been just getting the parts cleaned up and when I get the rebuilt, kit should go back together quickly..Just a matter of doing it..

I will let you know if I am looking for any parts, but for now I think I am looking pretty good..

[RANGERRICK]

Hello
It is not a replacement board,it is a kit that eliminates the board and uses a starter solenoid.

[RockwoodMike]

I would really like to know what that replacement kit is all about..Somebody jacked up all the wiring to the control board..There was a taped on toggle switch that powered the fuel pump..So to start it, switch the toggle, hit the starter button and off it ran..It had a remote starter panel inside the coach, but you till had to toggle the fuel pump..

Anyway, I will figure this all out..It is next on the list after I start the 440 up

[Eyez Open]

Go to smokestack, everything you want to know and then some. Those guys are fanatical.


https://www.smokstak.com/forum/forums/onan-generators.1/