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Onan MDJF Series, Operator'S Manual And Parts Catalog

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Onan MDJF Series Operator'S Manual And Parts Catalog Download Page 1

Summary of Contents for MDJF Series

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Page 2: ...L DONATED BY ED S THANK YOU ED If you need help with your old Onan visit the Smart Guys at The Stak They have many years of experience and they are happy to help http www smokstak com forum forumdispl...

Page 3: ...RTIFIED We certify that when properly installed and operated this Onan electric plant will deliver the full power and the voltage and frequency regulation promised by its nameplate and published speci...

Page 4: ...S EVERY OHAN UNIT BE RETAINED AND REFERRED TO WHEN MAKING EQUIPMENT ADJUSTMENTS OR ORDERING PARTS ADDITIONAL COPIES ARE AVAILABLE FOR A NOMINAL CHARGE FROM YOUR ON AN DISTRIBUTOR WHEN ORDERI NG PARTS...

Page 5: ...Onlln will und T thit warranty r pair or replst e 8 Onan may elt ut any Hart whirh on euminatiun hal dlsclo se to Onan 6 aatlM aetion to have bepn defective in material and workmanehip provide l that...

Page 6: ...nerator cooling air CFM at 1800 rpm 136 Combustion air CFM at 1800 rpm i 72 Total cu ft per min of air required 29 Diesel fuel lift maximum feet 6 Maximum recommended power take off from front pulley...

Page 7: ...Connecting Rod journal Diameter End Play Crankshaft PISTON Measure 90 to Pin Piston Clearance to Cylinder Wall below Oil Ring Groove Piston Pin Hole Diameter Ring Groove Width Top Ring Groove Width 2n...

Page 8: ...ring Tension VALVE INTAKE Hardened Chrome Alloy Stem Diameter Clearance in Guide Valve Face Seat Angle Valve Clearance VALVE EXHAUST Hardened Chrome Alloy Stem Diameter Clearance in Guide Valve Face S...

Page 9: ...htness without danger of stripping threads If a torque wrench is not available estimate the degree of tightness Use reasonable force and a wrench of normal length Special Place Bolts do not require lo...

Page 10: ...al Fire Protection Association International Boston 10 Massachusetts will be helpful to the installer of equipment in vessels LOCATION Select a location for the unit preferably near the vessels main k...

Page 11: ...amps to the mounting base For another engine use a separate fuel line and return line for each to avoid starving the plant Figure 4 maximum noise reduction on Onan MDJF units install the Onan Sound Sh...

Page 12: ...vide ventila tion when the boat is not in motioh For more information refer to Onan Technical Bulletin T 021 EXHAUST Pipe exbaust gases outside of tbe bull L ARNING exhaust gases are poisonous See Ins...

Page 13: ...cfeet see Figure 3 11 SHORT NIPPLE DOUBLE TAPPED TANK BUSHING LONG NIPPLE r INSIDE MUFFLER OUTLET I NOTE LONG NIPPLE GOES INSIDE TANK FIGURE 7 AQUA LIFT MUFFLER 3 Connect the exhaust line to the muffl...

Page 14: ...14 to 150 ft 12 to 280 ft 2 A719 DRAIN BLOCK HERE RUBBER HOSE LINE FROM WATER SOURCE 1 2 1 0 OR LARGER DRAIN HERE PRIMING PLUG EXHAUST MANIFOLD STARTING MOTOR STARTING MOTOR SOLENOID FIGURE 8 FiLL AN...

Page 15: ...ch SPDT momentary contact center off type to the terminal block marked B 1 2 3 in the set control box using wire sizes aslisted in Figure 9 Pre heat circuit requires an extra wire to terminal Hand mom...

Page 16: ...xi st or where the owner wants to prevent salt water problems Two conditions prevail 1 Factory installed heat exchanger and 2 Customer installed Dnan heat exchanger kit Get details from Dnan 1 Do not...

Page 17: ...ED LOAD WIRE BLACK T3 A A w at i i rGROUNDED LOAD WIRE WHITE O TO w z o A Nameplate lower voltage l phase circuit 8 Nameplate higher voltage 1 phase circuit 60 hertz 120 208volt model has code 4 Y Con...

Page 18: ...M SPECIFICATION A THROUGH C ENGINE DR IVEN WATER PUMP RAW WATER 6162 t INLET RAW WATER CENTRIFUGAL PUMP FRESH WATER BEGIN SPECIFICATION D __ BLEEDER VALVE FRONT CY LINDER BLOCK CONNECTION all EXHAUST...

Page 19: ...up crank engine one revolution to permit hand prim ing When finished return priming lever inward disengaged position to permit normal pump operation Temporarily remove the plug from the water pump inl...

Page 20: ...he unit s control box Nhich connects terminal H heater to terminal 3 start circuit and connect separate control pre heat circuit to the set H terminal when installing the control The time delay relay...

Page 21: ...eat exchanger 1 Remove fill cap 2 Open fill vent valve turn counterclockwise 3 Remove vent plug Spec A through C 4 Fill with coolant 5 Close fil vent valve turn clockwise 6 Replace vent plug Spec A th...

Page 22: ...Y CHARGED CONDI closed system coclling TION AND MAINTAIN CHARGE DURING STORAGE General LOW TEMPERATURES 1 Cover or seal all exposed openings exhaust outlet 1 Use correct SAE No oil for temperature con...

Page 23: ...itivity Adju stment To adjust governor sensitivity no load to full load speed droop turn the sensitivity ad justing ratchet Figure 18 Connterclockwise gives more sensitivity less speed drop when full...

Page 24: ...ition it will be in its power stroke with both valves Correct valve clearance is 017 intake and 017 completely closed exhaust 3 To change the setting of valve Clearance adjust the 5 Always adjust the...

Page 25: ...on lBO degrees one be between 10 and 45 degrees past the BC bottom half revolution The flywheel should be between 1 center flywheel mark and 45 degrees past the Be bottom center flywheel mark 7 After...

Page 26: ...COVER GASKET DRAIN ijiit BODY PLUG SECONDARY FUEl FILTER Spec A Only DUAL FUEL FILTER SYSTEM BEGIN SPEC 8 Drain water periodically as required Replace primary filter every six hundred 600 hours Perfor...

Page 27: ...fULL NEVER OPERATE ENGINE WITH OIL BELOW THIS LEVEL ___ t t_LOW ALWAYS REPLACE CAP TIGHTLY OR AS7 OIL LEAKAGE MAY OCCUR RESONATOR OIL LEVEL INDICATOR BREATHER TUBE CAP Remove breather cap Remove baffl...

Page 28: ...ulty is detected repair or service as required The generator set should be kept free of dust dirt and spilled oil or fuel Be sure proper operating procedure is followed WHAT TO CHECK HOW TO CHECK PREC...

Page 29: ...equired x Clean Rocker Box Oi I Line Holes x Check Nozzle Opening Pressure Spray Pattern x4 General Overhaul If Req x Change Fuel Filters xS x Perform as indicated on Table xl Replace collector ring b...

Page 30: ...g Thickness Pump Mounting Gaskets I I Defective 011 Gauge I 011 In C nkcase 1 011 Leaks F om Eng Ine Base 0 Light 0 Diluted C nkcase 011 OIlSeals I Ie I Imp ope Lub catlon FaullY 011 By Pass Ie Oll P...

Page 31: ...rest AUTHORIZED SERVICE STATION Print your name and address plainly on the package Write a letter to the same address stating the reason for returning the part 4 State definite shipping instructions A...

Page 32: ...0MDjF 54R 12 0MDjF 55DR 12 0MDjF 57R 15000 15000 15000 12000 12000 12000 12000 1201240 120 208 120 240 120 240 1201208 1201240 220 380 60 60 60 50 50 50 50 4 4 4 4 4 I 3 3 I 3 3 3 I 1 I I I I I 15 0MD...

Page 33: ...Valve 19 IIS OI96 2 Guide Push Rod 24 115 0197 2 Cover Rocker 25 120 0628 2 Line Oil Rocker Cover 26 115 0130 2 Gasket Rocker Cover 27 11 0 1264 10 Screw 3 8 16 x 4 1 4 Cylinder Head 28 800 0501 12 Sc...

Page 34: ...60 L61 2 r 11 I 8 j4 7 17 4 23 21 61 60 0 J o CRANKCASE AND OIL BASE GROUP 43 44 C b16 I r 60 61 34 33 18 l 50 21 _A 21 19 cx 49 I a 48 iJ 45 U 56 t58 57 32...

Page 35: ...g 21 123 0865 2 Baffle Breather Spec A through B 22 102 0539 Base Oil 23 102 0475 Gasket OJ I Base REF PART QTY PART NO NO USED DESCRIPTION 24 505 0056 I Plug 1 2 27 516 0141 2 Pin Gear Cover Locat jn...

Page 36: ...ting Forged 6 BEARING HALF CONNECTING ROD I 14 0164 8 Standard 114 0164 02 8 002 Undersize 114 0164 10 8 010 Undersize 114 0164 20 8 020 Unders ize 114 0164 30 8 030 Unders ize 7 f 14 0170 8 Bushing P...

Page 37: ...crew 7116 14 x 5_112 Flywheel 10 515 0001 Key Crankshaft Gear 12 850 0055 Washer Lock 7116 F Iywhee I Mounting 13 526 0185 Washer Flywheel Mounting 14 515 0153 Key F Iywhee I to Crankshaft 15 104 0444...

Page 38: ...luded in Control Assembly 16 160 0774 Plunger Thrust REF PART QTY PART NO NO USED DESCRIPTION 17 160 0773 Spring Thrust Plunger 17A 160 0906 I Disc Thrust Plunger 19 SOLENOID STOPPING 19 20 21 22 23 2...

Page 39: ...mp Lubrication Tee 27 CONNECTOR INVERTED MALE CYLINDER HEAD 502 Q274 I Rear Spec A Only 502 0281 I Rear Beg in Spec B 502 0281 I Front Begin Spec C 28 WASHER LOCK 850 0045 2 Oi I Pump Mounting 850 004...

Page 40: ...ng Elbow Inverted Male Water Pump Outlet Line Water Pump to Block Clamp Water Line Elbow Inverted M lle Water Line to Block Tee Male Cyl inder Block Water Inlet Rear REF E 28 29 30 31 32 33 34 35 36 P...

Page 41: ...AIR CLEANER AND FUEL FILTERS GROUP 50 1 51 I I 32 33 44 f 11 G 9 8 10 1 14 0 t 12 16 7 6 C 26 0 27 31 0 28 39 45...

Page 42: ...769 Plug Air Bleed Secondary Filter Spec A Only 30 502 0041 2 Elbow Inverted Male Secondary Filter Inlet 8 Outlet Spec A Only REF PART QTY PART NO NO USED DESCRIPTION 31 149 0408 Filter Secondary Fuel...

Page 43: ...liIFi 3Ii I j l 8 f FUEL TRANSFER PUMP AND INJECTION SYSTEM GROUP It _ r U iii ii I I f i i j j I h II f i I III j I 11 il i 1 I lli l 12 13 1 17 a14 ilhililell 32 10 41...

Page 44: ...tion Pump Pump Fuel Injection Pump Fuel Transfer Bowl Fuel Pump Metal 25 ELBOW INJECTION PUMP INLET 502 0054 I Spec A Only 502 0039 I Begin Spec B 26 BUTTON INJECTION PUMP PLUNGER 147 0147 I 147 0148...

Page 45: ...ncluded in the 131 0179 Repair Kit REF PART QTY PART NO NO USED DESCRIPTION MOTOR STARTER See Separate Group for Components 191 0324 I Key 1 12Volt 191 0443 I Key 2 24Volt 2 191 0512 I Flange Starter...

Page 46: ...I Nut 13 132 0139 I Lockwasher 14 132 0132 I Ring Snap Included in the 132 0093 Repair Kit WATER PUMP PARTS GROUP 132 0110 NOTE This pump used on un its with heat exchanger only REF PART QTY PART NO...

Page 47: ...132 126 13 132 127 14 132 128 15 850 1040 16 I 32 129 17 132 130 QTY PART USED DESCRIPTION I Pump Water Complete I Kit Repair Includes Parts Marked 4 Screw Cap I Ring Retainer Seat Seal I Bearing Bal...

Page 48: ...5 PLATE ASSEMBLY BRUSH J91 1025 I 12 Volt 191 1042 1 24Volt 6 191 1020 I Spring Set Brush Set of 4 7 191 1026 I Connector Package 8 191 0497 1 Bearing Bronze Drive End 9 191 1027 I Spring Plunger 10 1...

Page 49: ...ermosta Cover St ud Brass I 1 8 Diameter Brass 1 7 16 Diameter Elbow Brass Exhaust Manifold Water Outlet Hose Rubber 112 x 36 Water Outlet 8 Inlet I I 31 15 10 tl 13 I L tfl I I T2 r 14 c fol 19 22 2...

Page 50: ...1 Guard Belt 20 130 0692 Bracket Heat Exchanger Governor Spring 21 503 0217 Hose Rubber 3 4 1 0 x 56 Total length required for all hoses except raw water pump 21 503 0285 21 503 0478 21 503 0461 22 50...

Page 51: ...lbow Pump Inlet Outlet Spec A Only 44 502 0237 Elbow Raw Water Pump Outlet Begin Spec B 45 502 0370 Adapter Hose Raw Water Pump In let Beg in Spec B REF PART QTY PART NO USED DESCRIPTION 46 502 0372 B...

Page 52: ...HEAT EXCHANGER GROUP OPTIONAL EQUIPMENT BEGIN SPEC D 30 l 33 iJ 28 31 Q 24 123 301 33 32 31 31 J 34 21 7 13 1 3 1 j 31 8 i V 8 21 21 9 9 21 0 46 r 6 4 8 3 3 44 A 13 e 5 27 11 _ iw 50...

Page 53: ...03 0564 Hose 3 4 Exhaust Man ifold to Heat Exchanger REF PART QTY PART l Sh USED DESCRIPTION 503 478 I Hose 3 4 Cylinders 1 2 to Cyl inders 3 4 503 0472 Hose 3 4 Water Pump Outlet to Block 503 0699 Ho...

Page 54: ...tor Mounting 18 304 0006 2 Washer Resistor Centering 19 520 0620 I Stud Resistor Mounting 20 866 0001 I Nut Res istor Mounting REF PART QTY PART NO NO USED DESCRIPTION 21 870 0203 I Nut Rotor through...

Page 55: ...B Place Marker Strip Wire Holder Kit Battery Polarity Used on some early models Strip Marker B I 2 3 H Remote Control Str ip Marker 4 through 9 REF PART QTY PART NO NO USED DESCRIPTION 28 RESISTOR TA...

Page 56: ...28 4 2 16 J IS l 26 OPPOSITE SIDE 9A II 9 GENERATOR GROUP EXCITER PORTION 54...

Page 57: ...305 0264 305 0388 9 2 Rectifier Only Power Field Negative 305 0238 305 0238 305 0238 305 0238 9A 2 Rectifier Only Power Field Positive 305 0239 305 0239 305 0239 305 0239 9B 1 Rectifier Field Flash 3...

Page 58: ...is 1 112 Wide 320 0150 As Req 20 Amp 480Volt 320 0151 25 Amp 480 Volt 320 019 25Amp I 201240 Volt 320 Q20 35 Amp 120 240Volt 320 0153 40Amp 1201240Volt 9 REF PART GTY PART NO NO USED DESCRIPTION 320 0...

Page 59: ...lock 4 512 0042 1 Pu Iley Water Pump 16 502 0263 2 Elbow 900 318 I Exhaust 5 511 0068 I Belt Water Pump Drive Manifold I Block 7 502 0250 I Elbow Outlet Brass Pump 17 502 0085 1 Nipple 3 8 Exhaust Man...

Page 60: ...8 405 1515 Panel Engine End 862 0004 4 Set to Base 7 16 14 Insu lated 870 0053 I Band Mounting 10 32 9 405 1513 Panel Door Includes Air 22 503 0267 2 Clamp Hose Outlet Duct Insu lated 23 503 0691 I H...

Page 61: ...DESCRIPTION Decal Kit Gasket Kit Engine Overhau I Kit Eng ine Un its Without Heat Exchanger Spec A Only Overhaul Kit Engine Units Without Heat Exchanger Begin Spec B Overhaul Kit Engine Units With He...

Page 62: ...P REF PART QTY PART NO NO USED DESCRIPTION 30 502 014B 2 Elbow Male Secondary Filter Inlet Outlet Spec A Only 32 501 009B Line Flexible Transfer Pump to Secondary Filter Spec A Only 3B 501 0097 Line F...

Page 63: ...9 60 PART 1iQ 308 0155 307 0777 323 0052 307 0778 308 0069 332 0439 QTY PART DESCRIPTION Switch Alarm Test Relay Alarm Socket Alarm Relay Spring Alarm Relay Hold down Switch Hi Lo Charge Jumper Termin...

Page 64: ...1 j j j j j j j j j j j I j j j j j j j o j j j j j j j j...

Page 65: ...ir credit to the OnanAuthorized Distributor and his Approved or Registered Dealers for straight labor time when the cause of failure is deter mined 0 be defective material or factory workmanship This...

Page 66: ...allow warranty repair credIt to the Onan Authorized Dislributor and his Approved or Registered Dealers for straight labor LIme when the cause I r f lilure is deter mIned to be defective matelial or fa...

Page 67: ...MAINTENANCE A PI Wei nt oper ul In pr m hu tll produ t r L p nn d 2 pr rmd vid n of On n DJ I Ion ron Inn pol Minne...

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