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Onan DJA Series User Manual

Onan DJA Series
207 pages
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MANUAL
AND
PARTS
CATALOG
SERIES
DJA
INDUSTRIAL
ENGINES
0
FORM NUMBER
967-0413
Printed
in
U.S.A.
ISSUE DATE
5-79
(Spec A-T)
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Onan DJA Series Specifications

General IconGeneral
Cylinders2
CoolingAir-Cooled
Fuel SystemDirect Injection
Governor TypeMechanical
Engine TypeDiesel
Bore3.25 inches
StartingElectric
AspirationNaturally Aspirated
RotationCounterclockwise
Lubrication SystemPressure
Engine ModelDJA Series

Summary

General Information

Engine Specifications

Dimensions and Clearances

Assembly Torques and Special Tools

Engine Troubleshooting Guide

Installation Procedures

General Installation Planning

Recommendations for effective engine installation and compliance with codes.

Location and Mounting

Guidelines for engine placement, service access, and secure foundation mounting.

Ventilation and Exhaust Systems

Proper installation of ventilation for cooling and exhaust for safety.

Fuel Tank and Lines Installation

Guidelines for installing fuel tanks and lines, ensuring proper fuel delivery.

Battery and Electrical Connections

Proper mounting, wiring, and connection of batteries for the starting system.

Oil Drain Extension Installation

Instructions for installing an oil drain extension for service convenience.

Engine Operation

Crankcase Oil, Fuel, and Air Cleaner

Proper selection and use of oil, fuel, and air cleaner for engine operation.

Initial Start and Break-in Procedures

Steps for first start, break-in runs, and initial checks.

Starting, Stopping, and Load Application

Procedures for starting, stopping, and applying load to the engine.

Operating Conditions and Protection

Guidelines for operating in various environmental conditions and protecting the engine.

Service and Maintenance

Routine Engine Checks

Daily checks for oil, fuel, ventilation, connections, and battery.

Maintenance Schedules

Recommended schedules for operator and critical maintenance tasks based on operating hours.

Specific Maintenance Procedures

Detailed procedures for oil filter changes, breather cleaning, and air cleaner maintenance.

Cooling System

Cooling System Maintenance and Overheating

Maintaining cooling surfaces and understanding overheating causes and prevention.

Air Shutter and High Temp Cut-off

Details on the optional air shutter operation and high temperature cut-off switch.

Fuel System

Fuel Transfer Pump Service

Detailed instructions for removing, disassembling, repairing, and testing the fuel transfer pump.

Injection System Service and Timing

Procedures for injection nozzle and pump maintenance, timing, and installation.

Governor System

Governor Types and Operation

Description of governor types and their operational principles.

Governor Maintenance and Adjustments

Procedures for maintaining linkage, testing, adjusting speed, sensitivity, and solenoid.

Oil System

Oil Pump Service

Details on the oil pump's removal, repair, and installation.

Bypass Valve, Oil Lines, and Pressure Switch

Procedures for servicing bypass valve, oil lines, gauge, and pressure switch.

Starting System

Starting System Maintenance and Testing

Checks for wiring, commutator, brushes, battery, and voltage drops.

Starting Motor Component Service

Procedures for servicing armature, field coils, bearings, brushes, clutch, and solenoid.

Flywheel Alternator System

Alternator System Testing

Procedures for testing regulator-rectifier, stator continuity, and rotor magnetism.

Alternator Component Service and Maintenance

Maintenance for stator, rectifier, voltage regulator, and indicator light.

Engine Disassembly

Cylinder Head and Valve Maintenance

Procedures for checking valve clearance, testing compression, and cleaning components.

Valve and Seat Service

Detailed repair and installation procedures for valve guides, seats, springs, and seals.

Cylinder Head Disassembly and Installation

Procedures for removing and reinstalling the cylinder head assembly.

Internal Component Disassembly

Flywheel and Ring Gear Service

Steps for removing the flywheel and ring gear, including heating for installation.

Gear Cover and Governor Shaft Service

Procedures for removing and servicing the gear cover, oil seal, and governor shaft.

Governor Cup and Assembly

Instructions for removing, repairing, and installing the governor cup and assembly.

Piston, Rings, and Rod Assembly

Component Removal and Inspection

Steps for removing pistons, rings, rods, and inspecting cylinder, piston, and pin conditions.

Connecting Rod and Bearing Service

Procedures for cleaning and checking connecting rods, bushings, and bearings.

Assembly, Installation, and Break-in

Steps for assembling components, installing, and performing the engine break-in period.

Control System

Control System Maintenance

Guidelines for checking control system connections and contacts for tightness and cleanliness.

Parts Catalog

Ordering Repair Parts

Instructions for identifying and ordering replacement parts, including required information.

Wiring Diagrams

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