Onan MDJA User manual

Service
Manual
MDJA
MDJB
MDJC
MDJE
MDJF
MarineDiesel
GenSet Engines
974-0750
12-85
Printed in USA

Safety Precautions
Itis recommendedthatyou readyour engine manualand be-
come thoroughlyacquaintedwith your equipment beforeyou
startthe engine.
[awnR"cl This symbol is used throughout this
manual to warn
of possibleseriouspersonalinjury.
-1 This symbol refers to possible equip-
mentdamage.
Fuels,electricalequipment,batteries,exhaustgasesandmov-
ingpartspresentpotentialhazardsthatcould resultinserious,
personalinjury.Takecareinfollowingtheserecommendedpro-
cedures.
Safety Codes
All local, stateandfederalcodesshouldbeconsultedand
compliedwith.
Thisengineisnotdesignedor intendedforuse inaircraft.
Any such use is at theowner's sole risk.
General
Provideappropriatefire extinguishersand installthem in
convenientlocations. Usean extinguisherratedABC by
N FPA.
Makesurethatallfastenersontheenginearesecureand
accurately torqued. Keep guards in position over fans,
drivingbelts, etc.
If it isnecessaryto makeadjustmentswhiletheengineis
running, useextremecautionwhenclose
to hotexhausts,
movingparts, etc.
ProtectAgainst Moving Parts
0 Do notwear looseclothinginthevicinityof movingparts,
such as PTO shafts, flywheels, blowers, couplings,fans,
belts,etc.
Keepyour handsaway from movingparts.
Batteries
Beforestartingwork ontheengine, disconnect batteries
to preventinadvertentstartingof theengine.
DONOTSMOKEwhileservicingbatteries.Leadacidbat-
teriesgive
off a highlyexplosivehydrogengaswhichcan
be ignitedby flame, electrical arcingor by smoking.
0 Verify battery polarity before connecting battery cables.
Connectnegativecable last.
FuelSystem
DO NOT fill fueltanks while engine isrunning.
DO NOTsmokeor usean openflame inthevicinityof the
engine or fueltank. Internalcombustionenginefuels are
highlyflammable.
Fuel lines must be of steel piping, adequately secured,
and freefrom leaks. Pipingat the engine should be ap-
provedflexible line.
Do not usecopper pipingforflexible
lines as copper will work harden and become brittle
enoughto break.
Besure allfuelsupplies have
a positive shutoff valve.
#
ExhaustSystem
0 Exhaustproductsof any internalcombustion engine are
toxic andcan causeinjury, or deathif inhaled.Allengine
applications, especially those within a confined area,
shouldbeequippedwithan exhaustsystem
to discharge
gasesto the outsideatmosphere.
0 DO NOT use exhaustgasesto heat a compartment.
0 Makesurethatyour exhaustsystemisfreeof leaks. En-
sure that exhaust manifolds are secure and are not
warpedby bolts unevenlytorqued.
ExhaustGas
Is Deadly!
Exhaustgasescontaincarbonmonoxide,apoisonousgasthat
mightcause unconsciousnessanddeath. Itisan odorlessand
colorlessgas formed during combustionof hydrocarbonfuels.
Symptomsof carbon monoxidepoisoningare:
Dizziness 0 Vomiting
0 Headache 0 MuscularTwitching
0 Weaknessand Sleepiness
Ifyouexperienceany of thesesymptoms,get out intofreshair
immediately,shutdowntheunitanddonotuseuntilithasbeen
inspected.
The best protection against carbon monoxide inhalation is
properinstallationandregular,frequentinspectionsofthecom-
pleteexhaustsystem.
If younoticeachangeinthesoundorap-
pearance of exhaust system, shut the unit down immediately
andhave
it inspectedandrepairedatoncebyacompetentme-
chanic.
Cooling System
0 ThrobbinginTemples
0 Coolantsunderpressurehaveahigherboilingpointthan
water. DONOTopen a radiatorpressurecapwhen cool-
anttemperatureisabove
212 degreesF (1 00 degrees C)
orwhile engine
is running.
KeepThe UnitAndSurroundingArea Clean
0 Makesurethatoilyragsare notlefton or neartheengine.
Removeallunnecessarygreaseandoilfromtheunit.Ac-
cumulated grease and oil can cause overheating and
subsequentengine damage and presenta potentialfire
hazard.
Redistribution or publication of this document, 
by any means, is strictly prohibited.

Table of Contents
TITLE
General Information .................................................... 2
Specifications ......................................................... 3
Dimensionsand Clearances ............................................. 4
Assembly Torques andSpecial Tools .................................... 6
Serviceand Maintenance ............................................... 8
CoolingSystem ....................................................... 16
FuelSystem .......................................................... 36
GovernorSystem ..................................................... 60
EngineTroubleshooting ................................................ 7
ExhaustSystem ....................................................... 14
OilSystem ........................................................... 62
StartingSystem ....................................................... 68
EngineDisassembly ................................................... 75
INCORRECT SERVICE OR REPLACEMENT OF PARTS MIGHT RESULT IN
SEVERE PERSONAL INJURY AND/OR EQUIPMENT DAMAGE
. SERVICE
PERSONNELMUST BE QUALIFIEDTOPERFORMELECTRICALAND/OR
MECHANICALSERVICE
.
.
1
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by any means, is strictly prohibited.

General Information
INTRODUCTION
Thismanualdealswithspecificmechanicalandelec-
trical information needed by engine mechanics for
troubleshooting,servicing, repairing,or overhauling
the engine.
Usethetableof contentsfor aquick referencetothe
separateenginesystem sections.
Use the separate Parts Catalogs available at the
dealerlevel,for parts identificationandfor establish-
ingtheir proper locationon assemblies.
The
TROUBLESHOOTlNG GUlDE provides a quick
referencefor locatingandcorrectingenginetrouble.
The illustrations and procedures presented in each
sectionapplyto theengineslistedonthecover.The
flywheel end of the engine isthe front end,
so right
and left sidesare determined by viewing the engine
from the front.
The disassembly section contains major overhaul
procedures for step by step removal, disassembly,
inspection, repair and assembly of the engine
components.
Ifamajorrepairoranoverhaulisnecessary,acompe-
tent mechanicshould either do thejob or supervise
and checkthe work of the mechanicassignedtodo
thejob toensurethat alldimensions,clearancesand
torquevalues arewithin the specifiedtolerances.
Thewiringdiagramshowshowtheelectricalcompo-
nentsare interconnected.
Apartscatalog(availableatthedealerlevel)contains
detailed exploded views of each assembly and the
individualpiecepartnurnbersandtheirpropernames
for orderingreplacementparts.
Useonly GenuineOnan replacementpartstoensure
quality and the best possible repair and overhaul
results. When ordering parts, always use
the com-
pleteModelandSpecnumber
in additiontotheSerial
numbershownonthe nameplate.
ENGINEMODEL REFERENCE
Identifyyour model by referring to the MODEL and
SPEC (specification)
NO. as shown on the unit
nameplate. Always use this number and the engine
serialnumberwhenmakingreferencetoyourengine.
HowtointerpretMODELandSPEC
NO. ongenerator
set engines.
1.
2.
3.
4.
12.OiDJC
- f / 7 f
1 2 34
Factorycodefor generalidentificationpurposes.
SpecificTYPE, as follows.
R - REMOTE type. Electric starting. Optional
accessoryequipmentcan beconnectedfor
2
wire remotecontrol of startingand stopping
E - ELECTRIC starttype. Electricstarting at the
plantonly.
Factory code for specific optional equipment
supplied.
Specification (Spec Letter). Advances with fac-
tory productionmodifications.
2
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by any means, is strictly prohibited.

Specifications
All dimensionsin U.S. customary units of measure(metric in parentheses) unless otherwisespecified.
~~
UNIT OF
SPECIFICATION MEASURE MDJA MDJB MDJC MDJE MDJF
Numberof Cylinders 1 2 4 2 4
DieselFuel ASTM2-D ASTM2-D ASTM2-D ASTM2-D ASTM2-D
Bore in 3.25 3.25 3.25 3.50 3.50
(mm) (82.55) (82.55) (82.55) (88.9) (88.9)
Stroke
in 3.625 3.625 3.625 3.625 3.625
(mm) (92.07) (92.07) (92.07) (92.07) (92.07)
Displacement cu in 30 60 120 70
140
litre (0.5) (0.98) (1-9) (1 -2) (2.3)
CompressionRatio 19to
1 19 to 1 19to1 19to1 19to1
Firing Order 1-2-4-3 1-2-4-3
CrankshaftRotation
Governor VariableSpeed Mechanical Variable Speed Mechanical
Valve Clearance(Cold)
Spec A-C Begin Spec D *
Intake in 0.020 0.010 0.01
5
0.01 1 0.017 0.017
(mm) (0.51)
(0.25) (0.38) (0.28)
(0.43) (0.43)
Exhaust
in 0.020
0.010 0.01 3 0.01 6 0.017 0.017
(mm) (0.51) (0.25) (0.33) (0.41) (0.43) (0.43j .
OilFilter Full Flow FullFlow FullFlow Full Flow FullFlow
CrankcaseCapacity qt
3 3.5 . 6.5 3.5 6.5
(viewedfromflywheel) Clockwise Clockwise Clockwise Clockwise Clockwise
with filter change (I
i tre) (2.8) (3.3) (6.2) (3.3) (6.2)
3
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Dimensions and Clearances
All clearances given at room temperature of 70°F (21 "C) .
All dimensions in inches (millimeters in parentheses)unless otherwise specified .
CAMSHAFT
BearingJournal Diameter. Front ............................................. 2.2500-2.2505(57.150-57.163)
BearingJournal Diameter.Center (4 cylinder) ................................. 1.2580-1.2582(31-953-31.958)
BearingJournal Diameter. Rear ............................................. 1.1 875-1.1880(30.163-30.175)
BearingClearanceLimit(Original) .................................................. .0015-.0030 (-038-.076)
BearingClearanceLimit(Replacement) ............................................. .0012.. 0049 (.030-.123)
End Play .............................................................................. .007.. 039 (0.2-1.0)
Cam Tappet Diameter(Priorto Spec P) ......................................... .7475.7480 (18.987-18.999)
CamTappet Hole Diameter(Priorto Spec P) ................................... .7507.. 7515 (19.068-19.088)
Cam Tappet Diameter(BeginSpec P) .......................................... .8725.. 8730 (22.162-22.174)
Cam Tappet HoleDiameter (EeginSpec P) ..................... : ............... .8755.. 8765 (22.238-22.263)
Large BoreDiameter ..................................................... 2.1 871-2.1876 (55.5523-55.5650)
Small Bore Diameter ........................................................ 1.043-1.045(26.4922-26.543)
LargeBearingBoreto Small BearingBore
(Center-to-Center)
..................................................... 5.998-6.002 (1 52.3492-152.4508)
ConnectingRod End Play ............................................................. .002.. 016 (.05-.41)
Bore Honed Diameter(MDJA. MDJB. MDJC) ................................. 3.2495-3.2505(82.537-82.563)
Bore Honed Diameter(MDJE. MDJF) ........................................ 3.4995-3.5005(88.887-88.913)
MaximumAllowableTaper ................................................................. 0.005 (0.127)
MaximumAllowableOut-of-Round .......................................................... 0.001 (0.025)
Main BearingJournal Diameter (1 & 2 cylinder) ................................. 2.2437-2.2445(56.99-57.01)
Main BearingJournal Diameter (4 cylinder)................................... 2.2427-2.2435(56.965-56.985)
Center Main BearingClearance (4 cylinder) ......................................... .0024.. 0052 (.061-.132)
Frontand Rear MainBearingClearance(Original) (4 cylinder) ......................... .0030.. 0043 (.076-.109)
Main BearingClearance(Original) (1 & 2 cylinder) .................................... .002.. 0033 (.051-.084)
ConnectingRodJournalDiameter ........................................... 2.0597-2.0605(52.316-52.337)
Rod BearingClearance ............................................................ .001.. 0033(.025-.084)
EndPlay ........................................................................... .010.. 015 (.254-.381)
CONNECTING RODS
CY Ll NDER
CRANKSHAFT
Frontand Rear MainBearingClearance(Replacement) (4 cylinder) ...................... .0024-.0062(.06-.16)
Main BearingClearance(Replacement) (1 & 2 cylinder) ................................. .0014-.0052 (.04-.13)
PISTONSAND RINGS
ClearanceinCylinder
Measure
90' to pin.just below oil ring
RingGrooveWidth
(Priorto Spec
P). ............................................................... .0050.. 0070 (.127-.178)
(BeginSpec P) ................................................................. .0055-. 0075(.140-.191)
TOP ......................................................................... .0970.. 0980 (2.464-2.489)
NO . 2 ........................................................................ .0965.. 0975 (2.451-2.477)
NO . 3 ........................................................................ .0965-.0975 (2.451-2.477)
NO . 4 ........................................................................ .1880.. 1897(4.775-4.818)
RingGap ............................................................................ .010.. 020 (.25-51)
Clearancein Piston ..................................................................... Thumb-push Fit
ConnectingRod BushingClearance
................................................ .0002.. 0007 (.005-.018)
Rotation ............................................................................. Counterclockwise
PinionClearance
to PinionStop(SolenoidPlungerBottomed) ........................... .070.. 120(1.78-3.05)
Armature End Play .................................................................. .005.. 030(.030-.760)
PISTONPIN
STARTING MOTOR (prestolite)
4
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.
VALVE-INTAKE
Stem Diameter(Stemistapered)
Center .. .. .. . .. .. . . . . . . . . . . . . . .. . ... ... . . . . . . .. . . . .. .. .. . . .. . . . . . .. . . . .... .
-3401-.3411 (8.639-8.664)
**Face. . . .. . . .. .. .. . . . . . . . . . . . . . . ... . . . . . . .. . . . . .. .. ... . . .. . . . . . . . . . . . . . .. . . .
.3386-.3396(8.601-8.626)
Valve Face.. .. .. . . .. . . . . . . . . . . . . .. . . . .. . . .. . ... . . . . ....... . .. . ... . . .. . . .. . . . .. . .. . ... .. . . . .. . . . ..
42"
GuideClearance . ... . . . . . .. .. . . . . . . . .. .. . . . .. .. . . . . . . . .... . .. . .. .. . . . . . .. . . . . . . . .0015-.003(.038-.076)
Stem D iameter . . . .. . . .. . . .. . . . .. . . . . . . . . . . . .. . . . . . .. . . . . . . . .. . ..... . . . . . . . . . . .3405-.3415(8.649-8.674)
GuideClearance . . . .. . .. . .. .. . ... . . . .. . . . .. .. . .. . . .. . . . .. .. . . . . . .. . . . . . . . . . . . . .
-0030-.0050(.076-.127)
Valve Face ....................................................................................... 45"
Length . . . .. . . . . . . . ... .. . . . .. . . . . . .. . . . . . . . . ..... . ... . ....... . ... . . . ... . . . .. . . . .. . . . . 1.781 2 (45.2424)
OutsideDiameter . . . . . . . .. . .. . . . .. . . . . . . . . . . . . .. .. . .. .. . .. . .. . . ... . . . . . . .4690-.4695(11.91 26-11.9253)
InsideDiameter(after reaming)
Exhaust ..
.. . . . . .. . . . ...... . . . . . . . . . . .. . . .. . . . .. . ..... . .. . . . . .. . . . . . .. .. . . . .3445-.3455(8.750-8.776)
Intake . . . . ... .. . . . . . . .. .. .. . ... . ... . . .. . . .... . . .. .. . . . .. .. . . . .. .. . . .. . . . . . . .3425--3435(8.700-8.725)
Cylinder Block Bore Diameter.. . . .. .. . . , . . . . . . .. . . .. . . . . ... . . . . . . . .. . . . .. . . . .467-.468(11.8618-11.8872)
Valve Seat Bore(Diameter)
VALVE-EXH AUST
VALVE GUIDE
VALVE SEATS
Intake . .. . . .. .. . . . . . . .. . .. . . . . .. . .. . . . . . . ... .. . . .... .. . . ... . . .. .. . . . . . .. . . 1 S47-.1.548(39.29-39.32)
Exhaust . .. . . . . . .. . . . . . . . . .. . . .. . . . .. . . . . . .. .. . .. .. . . . . .... . . . . . . . . .. . .. . 1.361-1.362(34.570-34.595)
Depth(fromCylinderHead Face) . .. . . .. . . .. . . . . . .. . . . . . . . . .. . . . ... . . . .. . . . . . . . 43--439(10.99-11.15)
Exhaust . .. . . . .. . .. . . .. .. . . . .. . . . . .. .. . . . . . .. .. . .. . . . .. . . . . .... . . .. ... . 1.364-1.365(34.6456-34.6710)
Intake . . .. . .. . . . . . . . .. . . . . .. . . .. ..:. . . . . .. . . .. . . . . . . .. . . ... . . . .. . . . . .. .. . . . 1 -550-1-551(39.37-39.39)
Seat Width.. . . . . . . . .. . . . . .. . .. . . . . .. . . . .. . . . . ... . .. .. . .. . . .. .. . . .. . . .. . ... . . .... .
.047-.062(1.19-1.57)
Angle ............................................................................................. 45"
Available InsertOversizes.... .. . . . .... . . .. . . . .. . . ... .. . . . .. . .... . . . . . .. . . .. . . . .. . . ... . .. .. . ,002(.0508)
.005 (.127)
-010 (.254)
.025(.635)
Load-Valve Closed . .. . .. .. . . . .. .. .. . . . . .. . . . . . .. .. . . . . . . . . .... . .. . . .. . . . . . . . . , . 45-49 Ib (200-218 N*)
Load-Valve Open (Prior toSpec P) . .. .. . .. . . . . .. . .. . .. . . ... .. . .... . . ... . . . . . . . . . 83-93 Ib (369-414 N*)
Load-Valve Open (BeginSpec P). ... . . .. . . . ... . . . . . . . . .. . . . ... . . . . .. . . . . . . . ... . . 87-97 Ib (388-432 N*)
Seat Outside Diameter
VALVE SPRINGS
'Newton - Base unit of force.
"Measure intakevalve
stem at points indicated.
Valve Stem Diameter
(intake)
(75.2 mm)
1.18 IN
(30.0 mm)
5
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Assembly Torques and Special Tools
The assembly torques given herewill assureproper
tightness without danger of stripping threads. If a
torquewrenchisnotavailable,estimatethedegreeof
tightness necessary
for the stud, nut, or screw. Be
carefulnottostripthreads.Useonly reasonableforce
and awrench of normallength.
Speciallydesignedplaceboltsdo notrequirea lock-
washer orgasket.
Do notattempttouse a lockwasher
withthesebolts;itwill defeattheir purpose.Checkall
studs, nuts, andscrewsoften andtightenas needed
to keep them from working loose.
SPECIAL TOOLS
Thesetoolsare availablefrom Onanto aidserviceand
repairwork.
DieselNozzleTester
. . . . . . . ..... . . .. . .. . .420-0184
DieselPintleNozzleCleaning Tool Set
(includesinjectionnozzle
centeringtool) . .. . . .. .... . . .. . .. .. . . . . .420-0208
Driver, Center CamshaftBearing
(RDJFonly) .
.. . . . . . . . . .. .. .. . .. .. . ... .420-0254
Driver,Valve Seat . . . . . . . . .. . . . ... . . . ... . .420-0270
OilSeal Guide and Driver.. .. ... ... . . . . , . .420-0456
Nozzle Centering Sleeve. . . ... . .... . . . . . . .420-0321
DeliveryValve Test Fixture.. . . .. . . . . . .. . . .420-0322
Combination Mainand Cam
Bearing Driver......
. . .. . . . ... . . .. . .. . .420-0326
DieselCompressionTester ..... . . . . . . . . . .420-0283
Valve SpringCompressor Tool . . . .. . . . .. . .420-0119
Valve Seat Remover. .. . . . . . . ... . . . . . . .. . .420-0311
RECESS
UNDER HEAD
A749
TORQUE SPECIFICATIONS Ft.-Lb. Nom
Center mainbolt (4 cylinder) ... 97-102 (131-138)
Connectingrod bolt.. .. .. . . . .. . 27-29 (37-39)
Rocker-Box cover. . . . .. .. . .. .. . 8-1 0 (1 1-1 4)
Cylinderhead bolt .. . . . .. . .. . . . 44-46 (60-62)
Exhaust manifoldnuts.. . . . . .. . .
13-15* (18-20)
Flywheelmountingscrew.. . . . . . 65-70 (88-95)
Fuelpump mountingscrews . . . . 15-20 (20-27)
Gear case cover . .. . . .. . . .. . . . . 18-20 (24-27)
Injection nozzle mounting
screws .
. .. . .. . ... . .. .. .. . . . . 20-21 (27-28)
Injectionpumpmounting
screws .
. .. . . . .. . . . .. . . .. . . . .
15-1 6 (20-22)
Intakemanifold. . . . . .. . .. .. . . . . 13-15 (18-20)
Oil base mountingscrews .. . ... 45-50 (61-68)
Oilfilter .. . . . . .. .. . Handtight plus 114 to 1/2 turn
Oil pump mountingscrews . . . . . 15-20 (20-27)
Rear bearingplate . . .. . ... . . . .. 40-45 (54-61)
Rockerarm nut ..... .. .. . . . . .. .
4-lo** (5-13)
Rockerarmstud . . .. . . . .. . . . .. .
35-40 (48-54)
Glowplug . . .. .. . ... . . . . . . . .. . . 10-15 (18-20)
- Exhaust nutsmust betightened evenly.
FlywheelPuller . .. .. .... . . . .. .. . . . .. . .. . .420-0100
Crankshaft Gear Puller . . . . . . ... . .. . . . ... .420-0072
Crankshaft Gear PullingRing . . . . . . . . . . . .420-0248
Tool Catalog . .. . . ... . . . .... . .. . . .. . . . . . .900-0019
*' -This torque is dueto friction betwenthethreads only and
locksthenuts in place. Usethe rockerarmnut to adjustvalve
lash.
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Engine Troubleshooting
7
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Service and Maintenance
PRE-STARTING
Preparationsforthe initial andeachadditionalstart-
ingoperationshouldincludecarefulchecksoftheoil,
fuel, cooling, and electricalsystems.
Beforeengine is put inoperation, check all compo-
nentsfor mechanicalsecurity. Ifanabnormalcondi-
tion, defectivepart,oroperatingdifficultyisdetected,
repair or serviceas required.The engine should be
keptfree of dust, dirt, and spilled oil or fuel. Besure
properoperating procedureis followed.
Crankcase Oil
Multi-gradeoils (such as 5W-30) are recommended
for service in ambient temperatures of 32OF and
colder. OnOnan
J Dieselliquidcooledengines, SAE
15W-40or20W-40 oils (CD/SEServiceDesignation)
maybeused
in anambienttemperaturerangeof 15OF
(-10°C) through 90°F (32OC). Refer to the oil chart
belowfor recommendedviscosity grades at various
temperatureambients.
Useoilwithan API classificationofCD/SE (allviscos-
ity grades) or
CC/SE (grades 1OW-30, 1OW-40, or
5W-30 only).
When addingoilbetweenoilchanges, it ispreferable
to usethesame brand, as various brandsof oil may
not be compatible. Refer
to MaintenanceSchedule
for recommended
oil change intervals and pro-
cedures.
Crankcasepressure couldblow out
hot
oll and causeseflous,burns. Do
NOT check oil while the engine is operating.
Recommended Fuel
Use ASTM 2-D or 1-D fuel with a minimum Cetane
number of
45*. Number2 diesel fuel gives the best
economy for most operating conditions; however,
use
ASTM 1-D fuel during the following conditions:
1. When ambient temperatures are below 32" F
2. During long periods of light engine load; or no
(OOC);
load.
*NOTE FuelswithCetanenumbershigherthan45maybeneeded
inhigher altitudes or when extremely low ambient temperatures
are encounteredto preventmisfires.
Use low sulfur content fuel having a pour point
(ability to filter) of at least
10°F below the lowest
expectedtemperature. Keep thefuel clean and pro-
tected from adverse weather. Leave some room for
expansionwhen filling the fuel tank.
Duetotheprecisetolerancesofdie-
sel injectionsystems,it
is extremely
important the fuel be kept clean.
Dirt in the system
cancausesevere damage to both theinjectionpump
and the injectionnozzles.
WORK TRANSFERPUMP
PRIMINGLEVER UNTIL
FUEL FLOWS FROM
RETURN LINEFITTING
OF INJECTION PUMP.
FIGURE 1. BLEED FUEL SYSTEM
If the camshaft pumplobeisup, crank engine one revolution to
permithandpriming.When finished, returnpriming leverinward
(disengaged position)
to permitnormalpumpoperation.
8
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