Onan DJA Series Operating manual

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fDCSOD ^
MANUAL
AND PARTS CATALOG
SERIES
DJA
INDUSTRIAL ENGINES
0
FORMNUMBER
967-0413
Printed in U.S.A.
ISSUEDATE
5-79
(SpecA-T)

SAFETY PRECAUTIONS
Itis.recommendedthatyoureadyourenginemanualand
becomethoroughlyacquaintedwithyourequipmentbefore
youstarttheengine.
WARNING
This symbol
throughoutthis
is used
manualto
warnof possible serious personalinjury.
CAUTION
This symbol refers to possible
equipmentdamage.
Fuels, electricalequipment,batteries,exhaustgasesand
movingpartspresentpotentialhazardsthatcouldresultin
serious,personalinjury.Takecareinfollowingthese
recommendedprocedures.
SafetyCodes
•Alllocal,stateandfederalcodesshouldbeconsulted
andcomplied with.
General
•Provideappropriatefireextinguishersandinstallthem
inconvenientlocations.UseanextinguisherratedABC
byNFPA.
•Makesurethatallfastenersontheenginearesecure.
Tightensupportsandclamps,keepguardsinposition
overfans,drivingbelts,etc.
•Ifitisnecessarytomakeadjustmentswhiletheengine-
isrunning,useextremecautionwhenclosetohot
exhausts,movingparts,etc.
ProtectAgainstMovingParts
•Donotwearlooseclothinginthevicinityofmoving
parts, suchasPTOshafts,flywheels,blowers;
couplings,fans,belts,etc.
•Keepyourhandsawayfrommovingparts.
Batteries
•Beforestartingworkontheengine,,disconnect
batteriestopreventinadvertentstartingoftheengine.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesgiveoffahighlyexplosivehydrogengaswhich
canbeignitedbyflame,electricalarcingorbysmoking.
•Verifybatterypolaritybeforeconnectingbattery
cables.Connectnegativecablelast.
FuelSystem
•DONOTfillfueltankswhileengineisrunning,unless
tanksareoutsideenginecompartment.
•DONOTsmokeoruseanopenflameinthevicinityof
theengineorfueltank.Internalcombustionengine
fuelsarehighlyflammable.
•Fuellinesmustbeofsteelpiping,adequatelysecured,
and,freefromleaks.Pipingattheengineshouldbe
approvedflexibleline.Donotusecopperpipingon
flexiblelinesascopperwillworkhardenandbecome
brittleenoughtobreak.
•Besureallfuelsupplieshavea positiveshutoffvalve.
ExhaustSystem
•Exhaustproductsofanyinternalcombustionengine
aretoxicandcancauseinjury,'ordeathifinhaled.All
engineinstallations,especiallythosewithina confine,
.shouldbeequippedwithanexhaustsystemtodis-
chargegasestotheatmosphere.
•Donotuseexhaustgasestoheata compartment.
•Makesurethatyourexhaustsystemisfreeofleaks.
Ensurethatexhaustmanifoldsaresecureandarenot
warpedbyboltsunevenlytorqued.
EngineExhaustGas(CarbonMonoxide)isDeadly!
Carbonmonoxideisanodorless,colorlessgasformedby
incompletecombustionofhydrocarbonfuels.Carbon
monoxideisa dangerousgasthatcancauseun-
consciousnessandispotentiallylethal.Someofthe
symptomsorsignsofcarbonmonoxideinhalationare:
•Dizziness• Vomiting
•IntenseHeadache• MuscularTwitching
•WeaknessandSleepiness• ThrobbinginTemples
Ifyouexperienceanyoftheabovesymptoms,getoutinto
freshairimmediately.
Thebestprotectionagainstcarbonmonoxideinhalationis
aregularinspectionofthecompleteexhaustsystem.Ifyou
noticea.changeinthesoundorappearanceofexhaust
system, shut-theunitdownimmediatelyandhaveit
inspectedand'repairedatoncebya competentmechanic.
CoolingSystem
•- Coolantsunderpressurehavea higherboilingpoint
thanwater.DQNOTopena radiatorpressurecapwhile
theengineisrunning.Bleedthesystempressurefirst.
KeeptheUnitandSurroundingAreaClean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.

TABLE OF CONTENTS
TITLEPAGE
GeneralInformation2
Specifications3
DimensionsandClearances4
AssemblyTorquesandSpecialTools6
EngineTroubleshooting7
Installation8
Operation10
ServiceandMaintenance12
CoolingSystem14
FuelSystem16
GovernorSystem24
OilSystem27
StartingSystem29
FlywheelAlternator32
EngineDisassembly' 36
ControlSystem46
WiringDiagrams47
StartingGuide48
PartsCatalog49

DJASeriesengines are four cycle, vertical, air-cooled
dieselfueledengineswithoverheadvalves.The
crankcaseandcylinderareintegral.Enginesarerun
inandadjusted at thefactory.Anydamageincurredin
transitmustbecorrectedbeforeoperatingthe
engine.SeeFigure1 fora typicalmodelDJAIn-
dustrialEngine,
Normalenginespeed:range is: upto2400rpm.An
internal, constantspeed,flyball-typemechanical
governor,externally,adjustable,is standard: Optional
two-speedand:variable-speed:governorsare
available.
Wheninstructions,applytoa specificengine,model,
refertotheenginenameplatefortheModelandSpec
No. inquestion.
Throughout this, manual the flywheel end will be
calledthe front and the fuel pump side is designated
the/eff side-.. ,
TYPICAL MODELDJA
FIGURE1.' SERIESOJAINDUSTRIALENGINE
2

SPECIFICATIONS
Nominaldimensionsofengine(inches)
Height24-1/2(622mm)
Width19-1/8(486mm)
Length28-3/16(716mm)
ApproximateWeight(pounds)•..230(104kg)
NumberofCylinders•.1
Displacement(cubicinch)30(.49litre)
Bore3-1/4(82.55mm)
Stroke3-5/8(92.08mm)
HPat2400rpm(nominal)7.3(5.4kW)
CompressionRatio19:1
MainBearingsareSteel-BackedBronze,PrecisionTypefor
Replacement(quantity)2
ConnectingRodBearingsTri-MetalReplaceableYes
PistonRings(chromeplated)- 3rdCompressionRingNOTPlated
OilControl1
Compression3
HardenedChromeAlloyFacedValvesYes
HardenedChromeReplaceableValveSeats.•Yes
ValveRotator:Yes
Governor(internalflyballtype- externallyadjustable}Yes
NominalBatteryVoltage'.12
BatterySize
SAEGroupIHTwo
Amp/Hr.SAE20Hr.(nominal)105(378kC)
SolenoidShiftStarter' Yes
EnginecoolingairCFMat2400 rpm* ' 560(15.86rrvVmin)
Totalcubicfeetperminuteofairrequired613.8(17.38mVmin)
CombustionAirCFMat2400rpm21(.6mVmin)
InletVent(sq.ft.)7 (.7m2)
OutletVent(sq.in.)*64(.04m2)
GlowPlugandAirHeatertoAidStartingYes
InjectionPumpPLB
PrimaryandSecondaryFuelFiltersYes
FuelPumpLift6 ft.(1.8m)
OilPump(GearType)Yes
OilFilter(FullFlow)" Yes
OilCapacity(U.S.quarts)!2-1/2(2.4litres)
ExhaustConnection(Pipe-Tapped); 1-1/4(31.75)
PowerTake-off(inches)
ShaftLength4 (101.16mm)
ShaftDiameter1-3/4(44.45mm)
KeywayLength3 (76.2mm)
KeywayWidth3/8(9.5mm)
KeywayDepth3/16(4.76mm)
*- Pressure-cooledtypeairflow.
-Areawhenventiductisused;withoutduct,makeventaslargeaspossible.
t- Add1/2quart(.5litres)foroilfilter.
3

DIMENSIONSAND CLEARANCES
All clearances givenatroomtemperatureof70°F.
Alldimensionsin inches (metricsin parentheses) unless otherwise specified.
Minimum Maximum
CAMSHAFT
BearingJournalDiameter,Front.2.500(63.5mm)2.505(63.63mm)
BearingJournalDiameter,Rear 1.1875 (47.63mm) 1.1880 (30.18mm)
BearingClearanceLimit0.0012(.031mm)0.0037(.094mm)
EndPlay,Camshaft0.007(.18mm)0.039(.99mm)
CamTappetHoleDiameter0.7505(19.06mm)0.7515(19.09mm)
CamTappetDiameter0.7475(18.99mm)0.7480(19.00mm)
CONNECTING RODS
LargeBearingBoreDiameter2.1871(55.55mm)2.1876(55.57mm)
SmallBushingBoreDiameter1.044(26.52mm)1.045(26.54mm)
DistanceCenterLargeBearingBoretoSmall
BushingBore5.998(152.35mm)6.002(152.45mm)
Clearance,LargeBearingtoCrankshaft0.001(.03mm)0.003(.08mm)
CYLINDER
CylinderBore3-1/4(82.55mm)
CylinderDiameterLimits' 3.2495(82.54mm)3.2505(82.56mm)
CRANKSHAFT
MainBearingJournalDiameter2.2437(56.99mm)2.2445(57.01mm)
CrankshaftMainBearingClearance0.0014(.036mm)0.0052(.132mm)
ConnectingRodJournalDiameter2.0597(52.32mm)2.0605(52.34mm)
EndPlay,Crankshaft0.010(.25mm)0.015(.38mm)
PISTON
PistonClearancetoCylinderWall' 0.0055(.140mm)0.0075(.191mm)
PistonPinHoleDiameter0.9900(25.146mm)0.9903(25.153mm)
RingGrooveWidth,Top0.097(2.46mm)0.098(2.49mm)
2nd0.0965(2.45mm)0.0975(2.48mm)
3rd0.0965(2.45mm)0.0975(2.48mm)
4th0.1880(4.78mm)0.1895(4.81mm)
PISTON PIN
Length2.738(69.55mm)2.753(69.93mm)
Diameter! ' 0.9899(25.14mm)0.9901(25.15mm)
PistonClearanceThumbPushFit
ConnectingRodBushingClearance0.0002(.005mm)0.0007(.018mm)
PISTON RINGS
RingType
TopCompression
2ndCompression
3rdCompression
4thOilControl
RingWidth
Top0.0925(2.35mm)0.0935(2.37mm)
2nd, 0.0925(2.35mm)0.0935(2.37mm)
3rd0.0925(2.35mm)0.0935(2.37mm)
VALVE INTAKE(HardenedChromeAlloy Faced)
StemDiameter0.3381(8.59mm)0.3420(8.69mm)
ClearanceinGuide0.0005(.013mm)0.0025(.064mm)
SeatAngle42-degrees
ValveClearance0.011(.28mm)
4

VALVE, EXHAUST (HardenedChromeAlloy)
StemDiameter0.3405(8.65mm)0.3415(8.67mm)
ClearanceinGuide0.0025(.063mm)0.0045(.114mm)
SeatAngle45-degrees
ValveClearance0.008(.20mm)
VALVE GUIDE
Length• 1-25/32 (45.24mm)
OutsideDiameter0.4690(11.91mm)0.4695(11.93mm)
CylinderBlockBoreDiameter0.467(11.86mm)0.468(11.89mm)
InsideDiameter(afterreaming)
Exhaust0.344(8.74mm)0.345(8.76mm)
Intake0.342(8.69mm)0.343(8.71mm)
VALVE SEATS (HardenedChromeAlloy Faced)
ValveSeatBore
Diameter1.361(34.57mm)1.362(34.59mm)
Depth(fromcylinderheadface)0.433(11.00mm)0.439(11.15mm)"
SeatOutsideDiameter1.364(34.65mm)1.365(34.67mm)
SeatWidth- 3/64(1.19mm)1/16(1.59mm)
SeatAngle45-degrees
AvailableOversizes0.002(.05mm);0.005(.13mm);
0.010(.25mm);0.025(.64mm)-
VALVE SPRINGS
FreeLength1-7/8(22.23mm)
Length, ValveClosed1.528(38.81mm)
Load, ValveClosed45Ibs.(20.41kg)49Ibs.(22.23kg)
Length, ValveOpen1.214(30.84mm)
Load, ValveOpen83Ibs.(37.65kg)93Ibs.(42.18kg)
STARTING MOTOR
RotationCounterclockwise
PinionClearancetoPinionStop
(solenoidplungerbottomed)0.070(1.78mm)0.120(3.05mm)
PinionRestPosition- Distancefrompinionhousing
mountingfacetoouteredgeofpinion 1-9/32 (32.54mm) 1-15/32 (37.31mm)
ArmatureEndPlay005(.13mm)' .030(.76mm)
TestSpecifications
NoLoad10volts- 80amps(288kC)
5000rpmperMin.
StallTorque4 volts- 420amps(1512kC)
7.8ft.Ibs.perMin.(8.8N.m/min)
BrushSpringTension32-40oz.(.91kg- 1.13kg)
withnewbrushes

ASSEMBLY TORQUES
Theassemblytorquesgivenherewillassureproper
tightnesswithoutdangerofstrippingthreads.Be
carefulnottostripth reads. .Use reasonableforceonly
anda wrenchofnormallength.•
Speciallydesignedplacebolts(Figure2)donot
requirea lockwasherorgasket.Onanusesa-harden-
edflatwasherundereachboltto.preventgallingor
yieldingofbearingplatematerial..Donotattemptto
usea lockwasherwiththesebolts;itwilldefeattheir
purpose.Checkallstuds,nuts,andscrewsxrftenand
tightenasneededtokeepthemfromworkingloose.
FIGURE2.PLACEBOLT
TORQUESPECIFICATIONS FT. LBS.
ConnectingRodBolt27-29
Cover-RockerBox8-10
CylinderHeadBolt44-46
ExhaustManifoldNutsfl3-1-5
•FlywheelMountingScrew65-70
FuelPumpMountingScrews15-20
GearCaseCover18-20
GlowPlug10-15
InjectionNozzleMountingScrews....,20-21
InjectionPumpMountingScrews18-21
IntakeManifold13-15
Oil'BaseMountingScrews32-38
OilFilterHandTighten'+1/4to1/2Turn
OilPumpMountingScrews15-20
RearBearingPlate40-45
RockerArmNut*4-10
RockerArmStud35-40
t- Caution:Tightennutsevenlytoavoiddamage.
*- Thistorqueisfromfrictionbetweenthethreadsonlyandlocks
thenutinplace.Therockerarmnutsa'reforadjustingvalve
lash.
SPECIAL TOOLS
ThesetoolsareavailablefromOnantoaidserviceand
repairwork.
CrankshaftGearPullingRing420-0275
DieselNozzleTester.'.420-0184
DieselPintleNozzleCleaningTool
Set(IncludesInjectionNozzle
CenteringTool)420-0208
NozzleCenteringSleeve....-420-0321
.DeliveryValveTest'Fixturet420-0322
CombinationMainandCamBearing
Driver420-0326
•Driver,ValveSeat420-0270
OilSealGuideandDriver-
BearingPlate420-0250
GearCover420-0281
RidgeReamer420-0260
ReplacementCutterfilade
for420-0260.420-0261
"DieselCompressionTester...420-0283
ValveSeatRemover420-0311
ReplacementBladesfor420-0311420-0274
ValveGuideDriyer...:420-0300
t- Usedwithdieselnozzletester.

DefectiveFuelSystem
AirinFuelSystem
IncorrectTiming
RestrictedAirIntake- DirtyAirFilter
PoorQualityFuel
DirtyFuetFilters
OutcfFuelorShutOffClosed
WornorDamagedTransferPump,LeakingDiaphragm
FaultsInjectionPump,NozzlesorGaskets
FuelLineLeaks
WrongTimingButtoninInjectionPump
WrongThicknessPumpMountingGaskets
RunForLongPeriodsofTimeatNOLOAD
-OilSupply
DefectiveOHGauge
iOilinCrankcase
OilLeaksFromEngineBaseorConnections
LightorDilutedCrankcaseOil
LeakyOilSeals
FaultyOilBy-Pass
WornOilPump
HeavyOilorCloggedPassages
DirtyOilFilter KW.V.W.V.V.V;
•< GOVERNORSYSTEM
rDisconnectedLinkage
BindiigLinkage
:WearinLinkage
IncorrectGovernorAdjustment
HighSpringSensitivity
IncorrectlyInstalledGovernorYokeorCup
OverloadedGenerator
OLINCSYSTEM;
InsufficientCoolant
FaultyThermostat
WornWaterPumporDefectiveSeals
WaterPassagesRestricted
BlownHeadGasket
Overheating
RestrictedorTooLongWaterLines
DefectiveExpansionTankPressureCap
DirtonCoolingFins(AirCooled)
InadequateAirCirculation(AirCooled)
INTERNALENGINE
LoosePiston
LooseConnectingRodorCrankshaftBearing
Incorr-sctValveClearance
BrokenorWeakValveSpring
HighExhaustBackPressure
VaivesNotSeatingProperly
WornBearings
WornCylinderWalls,'Pistons.Rings
StickingValves
WornorDirtyValveGuides

INSTALLATION
GENERAL
Plantheinstallationcarefullytoensuremaximum
operatingefficiency.Usethismanualasa general
guide. Recommendationsinthismanualarebasedon
extensivetestsunderfavorableoperatingconditions.
Abidebypertinentlocalcodesregulatinginstallation
aridoperationofinternalcombustionengines.
Protectwallsandpartitionsthroughwhichexhaust
pipespasswitha metalshield(Figure3).
Installa suitablemufflerpreferablyasclosetothe
engineaspracticable.Pitchexhaustpipesdownward,
orprovidea condensationtrapatpointwherearisein
theexhaustsystembegins.
LOCATION
Enginelocationisdeterminedchieflybytheintended
application.Provideadequateaccessforserviceand
repair.Protecttheenginefromadverseweather.
Considerthelocationofrelatedsystems,suchas fuel,
exhaust,andventilation.
MOUNTING
Securetheenginetoa rigid, levelfoundation.Foun-
dationsmustbesturdyenoughtowithstanddistor-
tionandretainalignmentwithloadequipment.
Ifnecessarytoexceed23-degreetiltangle,consult
thefactory.Compensateforanytiltwhenchecking
crankcaseoil.
VENTILATION
Ventilationisneededtocooltheengineandsupport
combustion.Avoidrecirculationofventilatingair.See
SPECIFICATIONSsectionforairflowrequirements
andventsizes.
SINGLETHIMBLEDIAMETER12"
LARGERORDOUBLE
'•^VENTILATEDTHIMBLE
DIAMETER6"LARGER
THANEXHAUSTLINE
HOLESINEND
INNERSLEEVE
EXHAUST LINE PASSING THROUGH
|l WALL ORPARTITION
IFEXHAUSTLINEMUSTBEPITCHED
IUPWARDCONSTRUCTA TRAPOFPIPE
FITTINGSATPOINTOFRISE
AVOIDSHARPBENDS 1
DRAINCONDENSATIONTRAP
PERIODICALLY
-FIGURE3.EXHAUST
Locateventssoairflowfromtheinlettotheoutletwill
passovertheengine.Theoutletshouldbeslightly
higherthantheinlet.
Anoptionalairshuttermaybeusedintheoutletduct
tocontrolenginetemperaturebyregulatingairflow.
Airshuttersalsopreventbackflowofcoldairduring
engineshutdown.
Whenshuttersareusedbetweentheengineand
• outletvent,usea canvassectiontorestrictvibration.
EXHAUST
WARNING| Pipe9asou,sldeanyenclosure.Exhaustgas
^^n^^^^^Jispoisonous.
Exhaustpipesmustnotterminatenearinletvents.
Avoidsharpbendsbyinstallingsweeping,large
radiuselbows.Useflexibleseamlesssectiontubing
betweentheengineandanyrigidpipetorestrict
vibration. Increasetheexhaustpipeonesizeforeach
additional10-footlength.
FUEL TANKAND LINES
Installthefueltanksothattheverticaldistancefrom
bottomofthetanktothefuelpumpdoesnotexceed
sixfeet.Auxiliaryfuelpumpsareavailablewhich
provideanadditionaleight-footfuellift.
Avoidgravityfeedoffueltotheengine.Providea
siphonbreakiftankisabovepump.Whensharinga
fueltank,donotconnecttoanexistinglineata point
abovethefuelsupplylevel.
Thesedieselenginesrequirea fuelsupplylineanda
separatereturnline.Installthefuelsupplylinefrom
tanktothe 1/8-inch pipeinletinthefuelpump.
Connectthefuelreturnlinetothefitting(7/16-24
size)ontheinjectionpump(Figure4)tothetopofthe
fuelsupplytank.Useapprovedflexiblefuellinesat
theenginetoabsorbvibration.Besuretherearenoair
leaksinthesuctionline.