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Onan MDJE - Service Manual

Onan MDJE
92 pages
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Service
Manual
MDJA
MDJB
MDJC
MDJE
MDJF
Marine Diesel
GenSet
Engines
974-0750
12-85
Printed
in
USA
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Onan MDJE Specifications

General IconGeneral
BrandOnan
ModelMDJE
CategoryEngine
LanguageEnglish

Summary

Safety Precautions

Safety Codes

General safety guidelines and compliance with codes.

General Safety Procedures

General safety procedures and precautions for engine operation.

Protect Against Moving Parts

Precautions related to moving engine parts.

Battery Safety

Safety advice for handling and servicing batteries.

Fuel System Safety

Safety advice for the fuel system, including flammability.

Exhaust System Safety

Safety advice for the exhaust system, warning of toxic gases.

Exhaust Gas Hazard

Warning about exhaust gas toxicity and symptoms of poisoning.

Cooling System Safety

Safety precautions for the cooling system, especially pressure caps.

Cleanliness Precautions

Safety advice on keeping the unit and surrounding area clean.

Assembly Torques and Special Tools

Special Tools Listing

List of specialized tools for service and repair.

Torque Specifications

Torque values for engine fasteners.

Engine Troubleshooting Guide

Starting System Troubleshooting

Troubleshooting causes for starting system issues.

Fuel System Troubleshooting

Troubleshooting causes for fuel system issues.

Lubrication System Troubleshooting

Troubleshooting causes for lubrication system issues.

Governor System Troubleshooting

Troubleshooting causes for governor system issues.

Cooling System Troubleshooting

Troubleshooting causes for cooling system issues.

Internal Engine Troubleshooting

Troubleshooting causes for internal engine issues.

Service and Maintenance

Starting Procedures

Pre-Heating and Starting

Procedures for preheating and starting the engine.

Engine Failure to Start

Engine Maintenance Topics

Oil System Maintenance

Oil Filter Change Procedure

Procedure for changing the oil filter.

Unit Storage and Return to Service

Exhaust System

Exhaust System Installation

Cooling System

Draining the Cooling System

Procedures for draining the cooling system.

Cooling System Cleaning and Filling

Cleaning and Flushing Cooling System

Procedures for cleaning and flushing the cooling system.

Filling the Cooling System

Procedures for filling the cooling system with coolant.

Marine Cooling Systems

Marine Cooling System Types

Marine Cooling Water Flow

Marine Cooling System Components

Siphon Break and Heat Exchangers

Keel Coolers

Marine Water Pumps

Water Pump Repair Overview

General information on water pump repair.

Specific Water Pump Procedures

Metal Impeller Pump Procedures

Disassembly and assembly of metal impeller pumps.

Neoprene Impeller Pump #131-0152

Disassembly and assembly of a neoprene impeller pump.

Neoprene Impeller Pump #131-0257

Pump #131-0257 Disassembly and Assembly

Disassembly and assembly of a neoprene impeller pump.

More Neoprene Impeller Pump Procedures

Pumps #132-0146 and #132-0147

Disassembly and assembly of neoprene impeller pumps.

Pump #132-0059 Procedures

Disassembly and assembly of a neoprene impeller pump.

Cooling System Components Maintenance

Cooling System Pressure and Switches

Fuel System

Fuel Transfer Pump

Fuel Transfer Pump Description and Repair

Description, removal, and repair of the fuel transfer pump.

Injection Nozzles

Injection Nozzle Installation

Injection Nozzle Testing and Diagnosis

Nozzle Spray Pattern Check

Checking the nozzle spray pattern.

Using an Injection Nozzle Tester

Using a nozzle tester for diagnosis.

Nozzle Cleaning Procedure

Nozzle Cleaning Steps

Procedures for cleaning fuel injection nozzles.

Nozzle Repair and Fuel System Components

Nozzle Repair Procedures

Procedures for repairing fuel injection nozzles.

Fuel Solenoid Description and Testing

Description and testing of the fuel shutoff solenoid.

Fuel Injection Pumps Overview

Description of American Bosch fuel injection pumps.

MDJA Injection Pump Details

MDJA Injection Pump Repair

Recommendations for injection pump repair.

Injection Pump Timing Importance

Importance of timing the injection pump.

Injection Pump Installation Procedure

Installing the Injection Pump

Steps for installing the injection pump.

PSU;Model 50 Injection Pump Information

PSU or Model 50 Injection Pump Description

Description of PSU/Model 50 injection pumps.

Injection Pump Internal Operation

Fuel Injection Pump Timing

Timing PSU or Model 50 Injection Pumps

Timing by Calculation Method

Calculating timing button thickness.

Flow Timing Injection Pump Method

Alternative method for timing pumps.

Flow Timing Procedure

Step-by-Step Flow Timing

Step-by-step guide for flow timing an injection pump.

Bryce;Kiki Fuel Injection Pumps

Bryce;Kiki Pump Repair

Bryce;Kiki Pump Repair Recommendations

Recommendations for Bryce/Kiki injection pump repair.

Injection Pump Adapter Procedures

Injection Pump Adapter Assembly

Procedure for removing and installing the injection pump adapter.

Injection Pump Installation

Installing the Injection Pump on Adapter

Steps for installing the injection pump onto the adapter.

Pump and Adapter Assembly

Flow Timing for PC Point

Flow Timing Procedure for PC Point

Steps for determining PC point via flow timing.

Troubleshooting Pump Problems

Throttling Pintle Nozzle Tests

Tests for throttling pintle type nozzles.

Nozzle Testing and Adjustment

Nozzle Testing with Hand Tester

Testing nozzles using a hand tester.

Kiki Nozzle Adjustment

Adjusting Kiki nozzle opening pressure.

Yanmar;Bosch Nozzle Adjustment

Adjusting Yanmar/Bosch nozzle pressure.

Nozzle Performance Tests and Circuits

Governor System

Governor Sensitivity and Adjustment

Oil System

Oil Pump Description and Mounting

Description and mounting of the oil pump.

Oil Bypass Valve

Oil Pressure Switches

Centrifugal Switch Repair and Assembly

Starting System

Starting Motor Repair

Starting Motor Component Repair

Repair procedures for starting motor components.

Starting System Battery

Starting Motor Components Repair

Prestolite Starter Procedures

Prestolite Starter Removal and Disassembly

Steps to remove and disassemble the Prestolite starter.

Prestolite Starter Assembly

Assembly procedure for the Prestolite starter.

Mitsubishi Starter Procedures

Mitsubishi Starter Removal and Installation

Procedures for Mitsubishi starter.

Mitsubishi Starter Disassembly

Disassembly of Mitsubishi starter.

Mitsubishi Starter Assembly

Mitsubishi Starter Assembly Steps

Assembly of Mitsubishi starter.

Mitsubishi Starter Component Installation

Engine Disassembly

Engine Maintenance and Adjustments

Cylinder Head and Valve Disassembly

Cylinder Head Component Repair

Repair procedures for cylinder head components.

Valve Seat and Spring Procedures

Valve and Head Assembly

Procedure for valve and head assembly.

Valve Rotator and Decompression Release

Decompression Release Details

Internal Disassembly

Governor Cup and Piston Assemblies

Pistons, Rings, and Connecting Rods

Description of pistons, rings, and connecting rods.

Piston, Ring, and Connecting Rod Procedures

Connecting Rod Assembly and Camshaft

Camshaft Description

Description of the camshaft.

Camshaft Installation and Crankshaft

Crankshaft Description

Description of the crankshaft.

Crankshaft Procedures

Main Bearing Installation and Crankcase

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