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Onan MDKD Repairs


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  #21  
Old 12-09-2017, 10:15:02 AM
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Default Re: Onan MDKD Repairs

Be sure all connections are good. I ran into several with bad connections. Hit a wave and every thing shut down.
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  #22  
Old 12-09-2017, 08:47:55 PM
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Default Re: Onan MDKD Repairs

The marine manifold will work fine. I bet you dollars to donuts that the issue with the DJE is only a voltage regulator. I have found that 95 % of the time that is what it is with maybe another 4% the exciter coil and the remaining 1% is everything else. Cheers Dan
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  #23  
Old 12-10-2017, 08:16:56 AM
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Default Re: Onan MDKD Repairs

Thanks all

I will just use the Marine Exhaust Manifold. I was thinking it would be fine too, just wanted expert opinions.

I have checked every Safety Sensor, but have not had the time to try and start it again, but hoping to do that again soon. I am also in the middle of a Garage Re-arrangement (To much Crap) LOL

I think maybe my DJE could be the voltage regulator, but have not had the time to seriously check into it.

This is not a complaint, but it is a boat ride out and hope I bring everything to check it out with me. Diagnose, and hope I am right. I do have internet connection out there so that helps!

Then find and order the part, and then another boat ride out and try to see if it works....LOL I do fish and enjoy the nice Swamp while I am out there too so not all that bad

I just like to have a Genset as a backup plan just in case!!!
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  #24  
Old 12-16-2017, 04:06:46 PM
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Default Re: Onan MDKD Repairs

I have checked all of the sensors while it was running and they were good, but the fuel solenoid still will not hold.

I have a Control Board on the way. I am also making a new control box because the one that was on this Genset had been exposed to dripping water and was a total rust bucket.

I had a electric box in my shop that I cut down to size. I actually left it a little bigger so I have a bit of room in there if ever needed.

I am hoping soon to make this into a land based model!!!
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Old 12-16-2017, 04:39:24 PM
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Default Re: Onan MDKD Repairs

Does the solenoid hold when you power it directly, does the aux switch power up the hold section of the coil, when the coil is at full stroke ,the coil amps should drop to about 10% of the pull in amps if the coil is good. Cheers Dan
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  #26  
Old 12-16-2017, 08:06:04 PM
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Default Re: Onan MDKD Repairs

Did you rebuild the control box? If so, look for some polarity mistakes. If you get batt power reversed anywhere, you will get a machine that will crank, do glow and attempt to start, but the holding voltage on the fuel solenoid will go to zero if you release the start button and it will die.
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  #27  
Old 12-17-2017, 07:50:11 AM
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Default Re: Onan MDKD Repairs

I remember doing the test on the Solenoid and it holding but I will do it again today.

I am in the process of re-building the box. The way Onan laid this box out you can actually pull the box and not remove any wires. I am making my new box the same way. I will post some pics later today, it's pretty cool
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  #28  
Old 12-17-2017, 07:52:49 PM
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Default Re: Onan MDKD Repairs

The Solenoid holds when 12v is put to the positive. The reading I get when I push the rod full in are with the parameters you noted way back in post 5.

Thanks you for that information!!!

The last time I had it running it was producing 122 volts on both legs so I know the AC side is working.

I printed the schematic big at work and have that handy to ensure no reverse polarity on any of the wires as I remove and connect them to the new board and follow them to where they all go and check there too.

I have my new box all set up and painted. I also received the Control Board today, so tomorrow will be a big day when I get it put back together and try to keep it running.

Thanks all
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  #29  
Old 12-17-2017, 08:19:13 PM
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Default Re: Onan MDKD Repairs

You SHOULD NOT have to PUSH the rod full in, the pull in coil within the solenoid should be able to pull itself in along with the lever on the fuel pump it's attached to.
Then, the other seperate HOLD IN coil within the solenoid will draw less amps. the whole time the generator is operating.
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  #30  
Old 12-19-2017, 06:47:19 AM
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Default Re: Onan MDKD Repairs

Well it was not the Control Board...oh well. From the looks of the old one it may not have lived long anyways.

I re-checked the Fuel Shutoff Solenoid with it off of the Genset.

When I Ohm it out it starts at 1.6 and when pushed full in I get 17.7. How does this sound to the experts?

I am going to check the linkage on the Solenoid and also on the Lever to make sure I am getting the full throw to the bottom of the Solenoid.
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Old 12-19-2017, 08:53:55 AM
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Default Re: Onan MDKD Repairs

How about a picture of the back side of the solenoid??
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  #32  
Old 12-27-2017, 12:23:54 AM
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Default Re: Onan MDKD Repairs

Been awhile since I posted, but with the Genset in my head and the Holidays i have not had the time to catch up.

I got a new box made. I have attached old and new pics. I also got a Radiator from the Junkyard and made a bracket to hold it and Frankensteined some hoses to make it work. Came out good.

Now I am at my wits end I have chased every wire, no chafes, or grounding where it is not supposed to. I have bought a new board, CB12 Breaker and Stop Solenoid and it will still not hold the Solenoid in. I adjusted the actuator rod, checked and it is to spec....checked it again...then again

I checked the big 30 Amp fuse, it's fine. I checked the CB11 Off On Switch, it appears fine. I tested K14 Relay, and tripled checked the wiring to it. It all appears fine. I re-checked the Temp Sensor, it is in an NO Condition, I checked the Oil Pressure Switch, it's in a NC Condition. I Watched on my DVM and I could see S6 the Latch Control close as the engine ran and picked up oil pressure.

What am I missing?

And now my stupid pics are upside down Grrrrrrrrr!!~!!!!
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Last edited by Viking66; 12-27-2017 at 12:37:52 AM. Reason: Additional Info
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  #33  
Old 12-27-2017, 12:25:37 AM
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Default Re: Onan MDKD Repairs

More Pics...Upside down LOL
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  #34  
Old 12-27-2017, 12:37:40 AM
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Default Re: Onan MDKD Repairs

picture of the back side (wiring side) of the solenoid?????

The box looks good!

Pull in current is 30 amps, hold in current is .7 amps for the 1502 Woodward you have.
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  #35  
Old 12-27-2017, 07:08:38 AM
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Default Re: Onan MDKD Repairs

Back Side of the Solenoid.

The wire you see not connected is the Fuel Pump Wire. I have it connected directly to B+ as I run it and try to work out this crazy issue.

I also added a pic of the Control Box after I spent 2 hours chasing wires and making it more organized.

I removed the remote wires that will never be used, this helped me have more room. I kept the Remote Harness because you never know what the future will bring
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  #36  
Old 12-27-2017, 11:41:45 AM
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Default Re: Onan MDKD Repairs

Just because this thread is being a bit of a PITA to Viking66,,,

On the marine manifold water jacket. Is that isolated from the exaust outlet, or does it go to the elbow to dump the raw water overboard? Reason I'm asking,,, it'd sure be a great source of hot water for showers.
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  #37  
Old 12-27-2017, 01:47:59 PM
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Default Re: Onan MDKD Repairs

It is somewhat Isolated. The manifold and the water jacket are one piece except the back is bolted on. It could be done with a little engineering.

The exhaust goes through a smaller tube that is surrounded by the water jacket.

Yes it is being a pain, but I will take a pic for you later so you can see
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  #38  
Old 12-27-2017, 05:50:27 PM
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Default Re: Onan MDKD Repairs

Here is the Exhaust Manifold Pics.

Would not be as easy as I was thinking since the exhaust exit is made right into the water exit part. I was thinking if you removed the back there would be separate pipes for each.

I am guessing no one has any input to my issue I have been looking at the schematics and trying to figure it out, but nothing yet.

It would be cool to somehow use another relay and make it work, but I am not that smart...LOL
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  #39  
Old 12-27-2017, 10:02:08 PM
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Default Re: Onan MDKD Repairs

Is the solenoid new?

Do you happen to have a ammeter that could measure the draw in amps of the solenoid? Or an accurate clamp on ammeter.

While energizing the solenoid what is the voltage between the + and - terminals of the solenoid?

If it were mine I would take off all the wires going to the solenoid, get some smaller jumper cables and use the cables to activate the solenoid to see if it would work OK, then work back from there if it did work OK.

You also need to make sure that there is enough travel in the solenoid so that the fuel pump lever lets the solenoid bottom out when fully pulled in as to not burn up the pull in coil. This is mentioned and how to measure it in the attached instructions.

http://www.google.com/url?url=http:/...120OXGf6Vf_J3t
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  #40  
Old 01-06-2018, 11:14:50 PM
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Default Re: Onan MDKD Repairs

Any more progress on this??
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