Onan DJBA Series Instruction Manual

OPERATOR'S/SERVICE
MANUAL
AND PARTS CATALO i
SERIES
DJBA
INDUSTRIAL ENGINES
967-0423
ISSUEDATE
6-79
(SPECP-W)
Printedin U.S.A.

SAFETY PRECAUTIONS
• Itisrecommendedthatyouread'yourenginemanualand
becomethoroughlyacquaintedwithyourequipmentbefore
youstarttheengine.
WARNING
J
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.
Safety Codes
•Alllocal,stateandfederalcodesshouldbeconsulted
andcomplied with.
General
•Provideappropriatefireextinguishersandinstallthem
inconvenientlocations.UseanextinguisherratedABC
-byNFPA.
•Makesurethatallfastenersontheenginearesecure.
Tightensupportsandclamps,keepguardsinposition
overfans,drivingbelts,etc.
•Ifitisnecessarytomakeadjustmentswhiletheengine
isrunning,useextremecautionwhenclosetohot
exhausts,movingparts,etc.
ProtectAgainst Moving Parts
•Donotwearlooseclothinginthevicinityofmoving
parts, suchasPTOshafts,flywheels,blowers,
couplings,fans,belts,etc.
• Keep your hands away from movingparts.
Batteries
•Beforestartingworkontheengine,disconnect
batteriestopreventinadvertentstartingoftheengine.
•DONOTSMOKEwhileservicingbatteries.Leadacid
batteriesgiveoff a highlyexplosivehydrogengaswhich
canbeignitedbyflame,electricalarcingorbysmoking.
•Verifybatterypolaritybeforeconnecting
cables.Connectnegativecablelast.
Fuel System
battery
DONOTfillfueltankswhileengineisrunning,unless
tanksareoutsideenginecompartment.
•DONOTsmokeor'useanopenflameinthevicinityof
theengineorfueltank.Intemalcombustionengine
fuelsarehighlyflammable.
'• Fuellinesmustbeofsteelpiping,adequatelysecured,
andfreefromleaks.Pipingattheengineshouldbe
-approvedflexiblejine.Donotusecopperpipingon
flexiblelinesascopperwillworkhardenandbecome
brittleenoughtobreak.
•Be sure allfuel supplies havea positiveshutoffvalve.
Exhaust System
•Exhaustproductsofanyinternalcombustion.engine
aretoxicandcancauseinjury,ordeathifinhaled.All
engineinstallations,especiallythosewithina confine,
shouldbeequippedwithanexhaustsystemtodis-
chargegasestotheatmosphere.
•<*
•Donotuseexhaustgasestoheata compartment.
•Makesurethatyourexhaustsystemisfreeofleaks.
Ensurethatexhaustmanifoldsaresecureandarenot
warpedbyboltsunevenlytorqued.
Engine Exhaust Gas(Carbon Monoxide) 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, shuttheunitdownimmediatelyandhaveit
inspectedandrepairedatoncebya competentmechanic.
Cooling System
•Coolantsunderpressurehavea higherboilingpoint
thanwater.DONOTopena radiatorpressurecapwhile
theengineisrunning.Bleedthesystempressurefirst.
Keep theUnitandSurroundingArea Clean
•Makesurethatoilyragsarenotleftonornearthe
engine.
•Removealloildeposits.Removeallunnecessarygrease
andoilfromtheunit.Accumulatedgreaseandoilcan
causeoverheatingandsubsequentenginedamageand
maypresenta potentialfirehazard.

TABLE OFCONTENTS
TITLE PAGE
General Information 2
Specifications3
DimensionsandClearances4
AssemblyTorquesandSpecialTools6
DieselEngineTroubleshooting7
Installation8
Operation 10
Service and Maintenance 12
CoolingSystem14
FuelSystem16
GovernorSystem24
OilSystem27
StartingSystem30
Flywheel Alternator 34
Exhaust System37
EngineDisassembly38
ControlSystem48
Special Equipment50
DieselStartingGuide51
Wiring Diagrams52
PartsCatalog55

GENERAL INFORMATION
TheseinstructionsapplytotheDJBAindustrial
engine.Therearemanyoptionswhichcanbeadded
tothisengine.Identifyyourparticularmodelby
referringtotheunitnameplate.
HowtointerpretMODELand SPEC NO.
DJBA - MS/ 375W
1
3 4
1. Factorycodeforgeneralidentificationpurposes.
2. SpecificType:
MS- ELECTRICstartingwithstubshaft.
3.Factorycodeforoptionalequipmentsupplied.
4. Specification(SpecLetter)advanceswithfactory
productionmodification.
TYPICALDJBA ENGINE

SPECIFICATIONS
(All values givenin inches unless otherwisespecified.)
Dimensions
Height26(660mm)
Width18-3/8(467mm)
Length23-5/16(592mm)
Weight288(131kg)
NumberofCylinders2
Displacement(cu.in.)60(.98litre)
Bore3-1/4 (82.55 mm)
Stroke3-5/8(92.08mm)
H.P.at2400rpm(nominal)14.6(10.9kW)
CompressionRatio19:1
MainBearingsareLeadedBronze,PrecisionTypeforReplacement(Qty.) '. 2
ConnectingRodBearingsTri-MetalReplaceableYes
PistonRings(chromeplated)
OilControl1
Compression3
HardenedChrome- CobaltAlloyFacedValvesYes
HardenedChrome- CobaltAlloyReplaceableValveSeats'. Yes
ValveRotator, Yes
Governor(internalflyballtype- externallyadjustable)Yes
GovernorRegulation% 5
NominalBatteryVoltage-.12
BatterySize
SAEGroupIH(numberused)Two
Amp/Hr.SAE20hr.Minimum105(378kC)
SolenoidShiftStarterYes
EnginecoolingairCFMat1800rpm£ 590
Totalcu.ft.permin.ofairrequired613.8(17.38mVmin)
CombustionAir(cfm)* 42(.3rrvVmin)
CoolingAir(cfm)* 850(16.71mVmin)
InletVent(sq.ft.)7 (.7m2)
OutletVent(sq.in.)**80(.05m2)
AirCleaner(std.).'OilWetted
GlowPlugsandAirHeatertoAidStartingYes
InjectionPump(AmericanBoschType)PSU
PrimaryandSecondaryFuelFiltersYes
FuelPumpLift(Feet,maximum)6 (1.83m)
OilPump(GearType)Yes
Oil Filter (full flow) \es
OilCapacity(U.S.quarts)££3-I/3(3.3ntres)
ExhaustConnections(PipeTapped)1-1/4(31.75mm)
PowerTake-off(inches)
ShaftLength4 (101.I6mm)
ShaftDiameterI-3/4(44.45mm)
KeywayLength3 (76.2mm)
KeywayWidth3/8(9.5mm)
KeywayDepth> 3/16(4.76mm)
*- Airrequirementsat2400rpm.
**- Areawhenventiductisused;withoutduct,makeventaslargeaspossible.
£- Pressure-cooledtypeairflow.
££- Includes1/2quartfor(.47litres)foroilfilter.
3

DIMENSIONSAND CLEARANCES
(All values givenin inches unless otherwisespecified.)
MINIMUM MAXIMUM
CAMSHAFT
BearingJournalDiameter,Front.2.500(63.5mm)2.505(63.63mm)
BearingJournalDiameter,Rear•. 1.1875 (47.63mm) 1.1880 (30.18mm)
BearingClearanceLimit.0012(.031mm).0037(.094mm)
EndPlay,Camshaft.007(.18mm).039(.99mm)
CamTappetHoleDiameter8755(22.24mm).8765(22.26mm)
CamTappetDiameter8725(22.16mm).8730(22.17mm)
CONNECTING RODS
LargeBearingBoreDiameter2.1871(55.55mm)2.1876(55.57mm)
SmallBushingBoreDiameter1.044(26.52mm)1.045(26.54mm)
DistanceCenterLargeBearing
BoretoSmallBushingBore5.998(152.35mm)6.002(152.45mm)
Clearance,LargeBearingtoCrankshaft.0010(.025mm).0033(.084mm)
CRANKSHAFT
MainBearingJournalDiameter• 2.2437(56.99mm)2.2445(57.01mm)
CrankshaftMainBearingClearance.0020(.051mm).0033(.084mm)
ConnectingRodJournalDiameter2.0597.(52.32mm)2.0605(52.34mm)
EndPlay,Crankshaft.010(.25mm).015(.38mm).
CYLINDER
CylinderBore. 3-1/4(82.55mm)
CylinderDiameterLimits: 3.2495(82.54mm)3.2505(82.56mm)
PISTON
PistonClearancetoCylinderWall.0055(.140mm).0075(.191mm)
PistonPinHoleDiameter99005(25.15mm).99025(25.15mm)
RingGrooveWidth,Top.097(2.46mm).098(2.49mm)
RingGrooveWidth,2nd.0965(2.45mm).0975(2.48mm)
RingGrooveWidth,3rd0965(2.45mm).0975(2.48mm)
RingGrooveWidth,4th.1880(4.78mm).1895(4.81mm)
RingSideClearance.002(.051mm).006(.152mm)
PISTON PIN
Length: *.' 2.738(69.55mm.)2.753(69.93mm)
Diameter.-9899(25.14mm).9901(25.15mm)
PistomClearance@ 70°F " 00005 (.0013 mm).00025 (.0064 mm)
ConnectingRodBushingClearance.0002(.005mm).0007(.018mm)
PISTON RINGS
RingType
Topi Compression
2ndCompression
3rd• Compression
4thOilControl
RingWidth
Top.".0925(2.35mm).0935(2.37mm)
2nd0925(2.35mm).0935(2.37mm)
3rd• .0925(2.35mm).0935(2.37mm)
RingGapinCylinder.010(.25mm)
STARTING MOTOR
RotationCounterclockwise
PinionClearancetoPinionStop
(SolenoidPlungerBottomed).070(1.78mm).120(3.05mm)
PinionRestPosition- Distancefrom
.PinionHousingMountingFacetoOuterEdge
ofPinion 1-9/32 (32.54mm) 1-15/32 (37.31mm)
4

ArmatureEndPlay
TestSpecifications
NoLoad
StallTorque
BrushSpringTension
VALVE, INTAKE(Cobalt-ChromeAlloy)
StemDiameter
ClearanceinGuide
FaceAngle.',
ValveClearance(cold)
VALVE, EXHAUST (Cobalt-ChromeAlloy)
StemDiameter
ClearanceinGuide
Face Angle
ValveClearance(cold)
VALVE GUIDE
Length
OutsideDiameter
CylinderHeadBoreDiameter
InsideDiameter(afterReaming)
Exhaust
Intake—
VALVESEATS (Stellite)
ValveSeatBore
Diameter
Depth(fromCylinderHeadFace)
SeatOutsideDiameter
SeatWidth
SeatAngle
VALVE SPRINGS
FreeLength
Length, ValveClosed:
Load, ValveClosed
LengthValveOpen
Load, ValveOpen
VALVELIFTERS
LifterDiameter
LifterBore
OIL PUMP BYPASSVALVE
PlungerDiameter
SpringFreeLength
SpringTension(at 1-3/16 inchcompressed)
.005(.13mm) .030(.76mm)
10Volt-80Amps
5000rpmMinimum
4Volt- 420Amps
7.8ft.Ibs.Min.(10.6N«m)
32- 40oz.withnewbrushes
(.91kg-1.13kg)
.3405(8.650mm)
.0015(.038mm) 42°
.3410(8.66mm)
.0030(.076mm)
.009Intake(.229mm)
.3405(8.65mm).3415(8.67mm)
.0030(.076mm).0050(.127mm)
45°
.007Exhaust(.178mm)
1-25/32 (45.24mm)
.4690(11.91mm).4695(11.93mm)
.467(11.86mm)
.3445(8:75mm)
,3425(8.70mm)
1.361(34.57mm)
.433(11.00mm)
1.364(34.65mm)
3/64(1.19mm) 45°
.468(11.89mm)
.3455(8.78mm)
.3435(8.73mm)
1.362(34.60mm)
.439(11.15mm)
1.365(34.67mm)
1/16(1.59mm)
1-7/8(47.63mm)
1.528(38.81mm)
45(20.41kg)49Ibs.(22.23kg)
1.182(30.02mm)
87Ibs.(39.46mm)
.8725(22.16mm)
.8755(22.24mm)
97Ibs.(42.1848)
.8730(22.17mm)
.8765(22.26mm)
.3365(8.55mm).3380(8.59mm)
2-1/4(57.15mm)2-3/8(60.33mm)
2.225Ib.+ .11Ib.
(1.01kg+ .05kg)

ASSEMBLY TORQUES AND SPECIAL TOOLS
Theassemblytorquesgivenherewillassureproper
tightnesswithoutclangerofstrippingthreads.Use
reasonableforceonlyandawrenchofnormallength.
SpeciallydesignedPlaceBolts(Figure1)donot
requirealockwasherorgasket.Donotattempttouse
alockwasherwiththesebolts,itwilldefeattheir
purpose.Checkallstuds,nutsandscrewsoftenand
tightenasneededtokeepthemfromworkingloose.
RECESSED
UNDERHEAD
SPECIALTOOLSANDEQUIPMENT
ThesetoolsareavailablefromOnantoaidserviceand
repairwork.
CrankshaftGearPullingRing420-0275
DieselNozzleTester' 420-0184
DieselPintleNozzleCleaningToolSet
(IncludesInjectionNozzileCentering
Tool)420-0208
NozzleCenteringSleeve420-0321
DeliveryValveTestFixturet420-0322
CombinationMainandCamBearing
driver420-0326
Driver,ValveSeat* .420-0270
OilSealGuideandDriver
BearingPlate420-0250
GearCover420-0281
RidgeReamer420-0260
ReplacementCutterBlade
for420-0260420-0261
DieselCompressionTester420-0283
ValveSeatRemover420-0311
ReplacementBladesfor420-0311420-0274
ValveGuideDriver420-0327
FIGURE1.SPECIALPLACEBOLT t- Usedwithdieselnozzletester.
TORQUESPECIFICATIONSLB-FT
ConnectingRodBolt...27-29
Cover-RockerBox8-10
CylinderHeadBolt44-46
ExhaustManifoldNuts13-15**
FlywheelMountingScrew65-70
FuelPumpMountingScrews15-20
GearCaseCover18-20
GlowPlug10-15
InjectionNozzleMountingScrews......20-21
InjectionPumpMountingScrews15-16
IntakeManifold13-15
OilBaseMountingScrews45-50
OilFilterHandTight+1/4to 1/2Turn
OilPumpMountingScrews15-20
RearBearingPlate40-45
RockerArmNut4-10*
RockerArmStud35-40
-Thistorqueisfromfrictionbetweenthethreadsonly
andlocksthenutsinplace.Therockerarmnuts
areforadjustingvalve lash.
-Caution:Tightennutsevenlytoavoidmanifold
damage.

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TROUBLE -E
HardStartingorFailuretoStart
ExcessiveOilConsumptionLightBlueSmokyExh
ExcessiveOilConsumotionNoSmokeIncrease
ExcessiveFuelConsumptionBlackSmokyExhaust"
MechanicalKnocks
^Engme^sinr^^^^
^o^^neme^ower^
CoolingTemperatureTooHigh
bxcessiveFuelConsunption
FuelKnocks
bpeedTooMigh
SpeedTooLow
HuntingCondition
PoorSensitivity
NoGovernorControl
DilutedOil
CrankcaseSludge UUUHU
LowOilPressure
HighOilPressure
StarterMotorDoesn'tTurn
SlowStarterSpeed
Ttarte^Won^Pngag^^TywTieeF
PoorCompression
ValveBreakage
ValveBurning
PistonandCylinderandRingWear
WornConnectingRod,BushingsandBearings
StickingValves

INSTALLATION
GENERAL
Theinitialinstallationisveryimportant.Planit
carefullytoensuremaximumoperatingefficiency.
Usethismanualasa generalguide.Recommen-
dationsinthismanualarebasedonextensivetests
underfavorableoperatingconditions.Abidebyperti-
nentlocalcodesregulatingtheinstallationand
operationofinternalcombustionengines.
LOCATION
Enginelocationisdeterminedchieflybytheintended
application.Provideadequateaccessforserviceand
repair.Protectthetheehginefromadverseweather.
Considerthelocationofrelatedsystems,suchas fuel,
exhaustandventilation.
Pipeexhaustgasoutsideanyenclosure.Exhaust
pipesmustnotterminatenearinlet vents. Avoidsharp
bends;usesweeping,largeradiuselbows.Usea
sectionofseamless,flexibletubingbetweenthe
engineandanyrigidpipetorestrictvibration.In-
creaseexhaustpipeonesizeforeachadditional10
feetinlength.
Usea metalshieldtoprotectwallsandpartitions
throughwhichexhaustpipespass.SeeFigure2.
Installa suitablemufflerasclosetotheengineas
practicable.Pitchexhaustpipesdownward,or
providea condensationtrapatpointwherea risein
theexhaustsystembegins.'
MOUNTING
Securetheenginetoa rigid, levelfoundation.Foun-
dationsmustbesturdyenoughtowithstanddistor-
tionandtoretainalignmentwithcomplementary
equipment.
Ifnecessarytoexceed23°tiltangle,consultfactory
formaximums.Compensateforanytiltwhencheck-
ingcrankcaseoil.
SINGLETHIMBLEDIAMETER12"
LARGERORDOUBLE
VENTILATEDTHIMBLE
DIAMETER6"LARGER
THANEXHAUSTLINE
HOLESINEND
INNERSLEEVE
VENTILATION
Goodventilationisneededtocooltheengineandto
supportcombustion.Avoidrecirculationof ven-
tilatingair.SeeSpecificationsforairflowre-
quirementsandventsizes.
Locateventssotheflowofairfromtheinlettothe
outletwillpassovertheengine.Theoutletshouldbe
slightlyhigherthantheinlet.
Anoptionalairshuttermaybeusedintheoutletduct
tocontrolengine tem rperaturebyregulatingairflow.
Airshuttersalsopreventback-flowofcoldairduring
engineshut-down.
Whenusingventiductsbetweentheengineandoutlet
vent,provideasectionoffcanvastorestrictvibration.
EXHAUST
WARNING Pipeexhaustgasesoutofanyenclosure.
Inhalationofexhaustgasescanresultin
seriouspersonalinjury.
FIGURE2.EXHAUSTLINEPASSINGTHROUGH
WALLORPARTITION
FUEL TANKAND LINES
Wherea separatefueltankisused,installsothe
verticaldistancefrombottomofthetanktothefuel
pumpdoesnotexceed6 feet. Auxiliaryfuelpumpsare
availabletoprovideanadditional8 footlift.
Avoidgravityfeedoffueltotheengine.Providea
siphonbreakiftankisabovepump.Whensharinga
fueltank,donotconnecttoanexistinglineata point
abovethe.fuelsupplylevel.
Thesedieselenginesrequirea fuelsupplylineanda
separatereturnline.Installthefuelsupplylinefrom
tanktothe1/8"pipeinletinthefuelpump.Connect
fuelreturnlinetofittingatinjectionpump,seeFigure
3.Useapprovedflexiblefuellinesattheengineto
absorbvibration..Besuretherearenoairleaksinthe
suctionline.Installa shut-offvalveinthetankfor
serviceconvenience.