Page 1: ...O P E R A T O R S S E R V I C E MANUAL AND PARTS CATALO i SERIES D J B A INDUSTRIAL ENGINES 967 0423 ISSUE DATE 6 79 SPEC P W P r i n t e d in U S A...
Page 2: ...Fuel lines must be of steel piping adequately secured and free from leaks Piping at the engine should be approved flexiblejine Do not use copper piping on flexible lines as copper will work harden an...
Page 3: ...iesel Engine Troubleshooting 7 Installation 8 Operation 10 Service and Maintenance 12 Cooling System 14 Fuel System 16 Governor System 24 Oil System 27 Starting System 30 Flywheel Alternator 34 Exhaus...
Page 4: ...rticular model by referring to the unit nameplate How to interpret MODEL and SPEC NO DJBA MS 375W 1 3 4 1 Factory code for general identification purposes 2 Specific Type MS ELECTRIC starting with stu...
Page 5: ...mber used Two Amp Hr SAE 20 hr Minimum 105 378 kC Solenoid Shift Starter Yes Engine cooling air CFM at 1800 rpm 590 Total cu ft per min of air required 613 8 17 38 mVmin Combustion Air cfm 42 3 rrvVmi...
Page 6: ...mm 015 38 mm CYLINDER Cylinder Bore 3 1 4 82 55 mm Cylinder Diameter Limits 3 2495 82 54 mm 3 2505 82 56 mm PISTON Piston Clearance to Cylinder Wall 0055 140 mm 0075 191 mm Piston Pin Hole Diameter 9...
Page 7: ...MP BYPASS VALVE Plunger Diameter Spring Free Length Spring Tension at 1 3 16 inch compressed 005 13 mm 030 76 mm 10 Volt 80 Amps 5000 rpm Minimum 4 Volt 420 Amps 7 8 ft Ibs Min 10 6 N m 32 40 oz with...
Page 8: ...iver Valve Seat 420 0270 Oil Seal Guide and Driver Bearing Plate 420 0250 Gear Cover 420 0281 Ridge Reamer 420 0260 Replacement Cutter Blade for 420 0260 420 0261 Diesel Compression Tester 420 0283 Va...
Page 9: ...c e s s i v e F u e l C o n s u n p t i o n F u e l K n o c k s bpeed T o o Mi gh Speed T o o L o w H u n t i n g C o n d i t i o n Poor S e n s i t i v i t y No G o v e r n o r C o n t r o l D i l u...
Page 10: ...LARGER OR DOUBLE VENTILATED THIMBLE DIAMETER 6 LARGER THAN EXHAUST LINE HOLES IN END INNER SLEEVE VENTILATION Good ventilation is needed to cool the engine and to support combustion Avoid recirculati...
Page 11: ...arting motor solenoid Figure 4 OIL DRAIN EXTENSION For service convenience install an oil drain extension made from standard pipe and fittings in the 1 2 pipe tapped oil drain hole in the oil base STA...
Page 12: ...itions 1 When ambient temperatures are below 32 F 0 C 2 During long periods of light engine load or no load NOTE Fuels with Cetane numbers higher than 45 may be needed in higher altitudes orwhen extre...
Page 13: ...until thoroughly warm 2 Drain the oil base while still warm Attach a warning tag to refill before operating 3 Service the air cleaner 4 Lubricate governor linkage Protect from dirt by wrapping with a...
Page 14: ...alified service personnel OPERATOR MAINTENANCE SCHEDULE CRITICAL MAINTENANCE SCHEDULE MAINTENANCE ITEMS OPERATIONAL HOURS MAINTENANCE ITEMS 8 50 100 200 600 3000 Inspect Engine X Check Fuel x3 Check O...
Page 15: ...P IN ENGINE OIL AND SQUEEZE AS DRY AS POSSIBLE F U E L F I L T E R S C O N N E C T O R F r o m fuel t r a n s f e r p u m p E L B O W To i n j e c t i o n p u m p P R I M E C O N D A R Y F I L T E R D...
Page 16: ...e losing speed momentarily or low engine power This happens befbre the engine seizes and results in scored pistons AIR DUCT AND SHUTTER BLOWER HOUSI NG FIGURE 9 OPTIONAL SHUTTER ASSEMBLY The most prob...
Page 17: ...t 7 32 Do not overheat If the unit will not close check for a weak return spring binding in the nylon bearings or dirt in the power element plunger If the nylon bearings are worn or bind replace them...
Page 18: ...opening any part of the fuel system beyond the secondary fuel filter place all parts in a pan of clean diesel fuel as they are removed Before installing new or used parts flush them thoroughly and in...
Page 19: ...agm Overhaul the pump and replace the defective parts Low pressure with little or no pressure leak after pumping stops indicates a weak or broken spring or worn linkage and in most cases the pump shou...
Page 20: ...roximately 1750 psi Do not disassemble the nozzle or adjust nozzle pressure without proper test equipment A nozzle pressure tester is essential to do this work inspection To inspect the nozzle spray p...
Page 21: ...nozzle assembly from the engine and remove the fuel inlet and return lines 2 Clamp the nozzle holder body in a vise and remove the nozzle cap nut and nozzle 3 Install the nozzle cap nut loosely to pro...
Page 22: ...uld be about 1 amp If it is much greater the contacts did not open Adjust the solenoid plunger so it fully stops injection when in the de energized position To adjust the plunger length screw the hex...
Page 23: ...the port closing dimensions and button number of the old Dump were recorded Use Method 2 if thedimensions are lost and old pump is being retimed or when replacing either the camshaft or crankshaft Rem...
Page 24: ...r while turning the flywheel clockwise until fuel stops coming out of the injection line This is the port closing point or the point where injection begins 5 Check the position of the port closing mar...
Page 25: ...ips into place locking the gear in position 5 Mount the pump on the crankcase be sure the shims are in place and secure with screws If the O ring between pump and crankcase is worn cracked or otherwis...
Page 26: ...NKAGE GOVERNORS The constant speed governor F igure 25 maintains engine speed up to 2400 rpm The speed sensing device is a ball ahd cup mechanism on the camshaft gear A yoke resting on the cup is conn...
Page 27: ...spring tension and checking ball joints To test spring rates use a spring type scale Compare the measured rated with those in Table 3 TABLE 3 GOVERNOR SPRING DATA GOVERNOR TYPE SPRING NO SPRING RATE...
Page 28: ...mal force on the governor arm auxiliary spring holding the governor wide open for high speed operation When de energized the solenoid spring forces the plunger out relaxing the auxiliary spring Adjust...
Page 29: ...Because it aids oil consumption control the crankcase breather is included in the oil system Normal oil pressure should be 25 psi or higher when the engine is at operating temperature If pressure dro...
Page 30: ...asher 4 Loosen two cap screws holding the pump and lift out Repair parts for the pump are not individually available except for gaskets If thepump is excessive ly worn replace it Disassemble the pump...
Page 31: ...operation A clogged breather pipe may result in oil leakage at the rocker box gaskets and oil filter seal FIGURE 30 ROCKER BOX OIL LINE OIL PRESSURE GAUGE The gauge is located on thelower front cylind...
Page 32: ...ar and reduced armature seating Test for poor cranking performance caused by a faulty starting motor defective battery or high resistance in the starting circuit Battery charge condition should be tes...
Page 33: ...e starter mounting flange Then pull starting motor off the engine 5 Remove link pin holding shift lever to solenoid plunger and remove the shift lever pivot pin See Figure 34 6 Extract thru bolts from...
Page 34: ...ates a grounded armature See Figure 35 Use a growler to test forshorted coils Placearmatu re in growler and run a steel strip over the armature surface If a coil is shorting the steel strip becomes ma...
Page 35: ...otors check this gap II it is too great a shim kit is available to reduce it Figure 38 Over running Clutch Over running clutch should be thoroughly cleaned do not dip in solvent It can t be repacked w...
Page 36: ...fore performing following tests 1 Connect an ammeter between the red terminal on the rectifier and the ignition switch 2 With the engine running at 1800 rpm the ammeter should indicate about 8 amperes...
Page 37: ...tely isolatethe rectifierassemblyfrom the charging circuit by disconnecting all four wires Test each rectifier separately with an ohmmeter or test lamp Figure 40 2 With an ohmmeter connect one test le...
Page 38: ...eated Stator Tests Fortesting use a Simpson 260 VOMorequivalent Be sure test meter and battery if battery powered are in good condition Check with engine NOT running 1 Set voltage selector switch to D...
Page 39: ...installing an adapter or tee in the exhaust line at the manifold Connect a manometer or pressure gauge to the adapter If there is a condensation trap next to the manifold use it for the manometer con...
Page 40: ...the flywheel mounted remove the head and install adepth gauge over the front piston Rotate the flywheel to find the TDC position on the compression stroke and mark this point oh the flywheel Next tur...
Page 41: ...flyballs that have flat spots or grooves Replace the cup if the race surface is grooved or rough The governor cup must be free spinning fit on the camshaft center pin but should be replaced if excess...
Page 42: ...g each valve tip releases keepertension as the valve is pushed off its seat This allows the valve to float in its guide Engine vibration and cylinder air flow cause the valve to rotate while floating...
Page 43: ...with 240 320 grit emery cloth Check refinished valve foratightseatto the valve seat with an air pressure type testing tool or by applying Prussian Blue on the valve face and rotating it against the se...
Page 44: ...6 ft lbs following the sequence in Figure 50 6 Install the exhaust manifold nozzles glow plugs and oil lines 7 Install the valve stem caps 8 Install the push rods rocker arms and rocker arm nuts 9 Set...
Page 45: ...s of the rings Do not use rings that need a lot of filing they will not seat right on the cylinder walls If oversize pistons are used use the correct oversize rings See Figure 51 CAST IRON OIL CONTROL...
Page 46: ...d cap position so the raised witness mark on the forging matches the mark on the connecting rod Figure 53 6 Tighten the cap screws to the specified torque 7 Crank the engine over by hand to see that a...
Page 47: ...CAMSHAFT BEARINGS CRANKSHAFT The DJBA series engines use a counter balanced ductile iron crankshaft To increase the shaft s fatigue durability all crankpin fillets are shot peened during manufacturing...
Page 48: ...al procedures must be observed when rework ing diesel crankshafts In addition to machining the crankshaft must be shot peened and super finished Failure to shot peen the crankpin fillets is likely to...
Page 49: ...lace Install the retaining washer and lock ring 6 Check the crankshaft end play Use enough rear bearing plate gaskets or shims and gaskets to provide 010 to 015 end play If gaskets of more than 015 to...
Page 50: ...t off switch during starting to allow the engine to build up oil pressure and close switch The switch closes at 14 1 psi under in creasing pressure If oil pressure falls below 14 1 psi the switch open...
Page 51: ...ker plate and set the gap at 020 6 Install switch cover and reconnect battery REPAIR Thoroughly clean the gear and cam assembly the bearing surfaces in the gear case and breaker plate and oil trickle...
Page 52: ...shaft and release bearing Disassembly After clutch has been removed from flywheel place on bench or flat surface with release bearing up During disassembly identify all parts so they can be returned t...
Page 53: ...ENGINE DOES NOT START IF ENGINE FIRED REPEAT ABOVE PROCEDURES INCLUDING PRE HEAT IF IT STILL DOES NOT START PROCEED AS FOLLOWS TEMPERATURES BELOW 32 F 0 C USE NUMBER 1 DIESEL FUEL USE CORRECT VISCOSI...
Page 54: ...W P L U G S W I T C H N J 3 0 8 A 2 a RECTI Fl EW v t t 2 H _ J H FUEL SOLENOID 1 J O A FUSE N FUSE HOLDER 3ZIP IS4V 6 I MS 1 2 S L 0 W P L U G S N 3 3 3 B I 0 3 i f T A R T S w M A N i r O L D M E A...
Page 55: ...OI FlTIHEEL Hftl 3 nue SLOi HM i HEMER MNIFLOO I I S07B6ZB Ktr 1 S L M l4 ruEl SI 3M12S i SflTCH ClOl PIUG S2 10 P7 i SIIICK fUlL SOIEMOIO S3 308 198 i siiTcn sraaT 55 i SIITCK IOI OIL PkESSURE Ml i W...
Page 56: ...3 Give the part number description and quantity needed of each item If an older part cannot be identified return the part prepaid to your dealer or nearest AUTHORIZED SERVICE STATION Print your name...
Page 57: ...tems Each illustrated part is identified by a reference number corresponding to the same reference number in the parte list for the group Parts illustrations represent typical items and do not necessa...
Page 58: ...0681 1 Specs P and R 123 1085 i 1 Begin Spec S 15 123 0667 1 Gasket Oil Fill Tube 16 CAP AND INDICATOR OIL FILL 123 0651 1 Specs P and R 123 1058 1 Begin Spec S REF PART QTY PART NO NO USED DESCRIPTI...
Page 59: ...29 115 0127 115 0150 115 0152 115 0149 115 0195 115 0196 COVER ROCKER 115 0134 115 0199 120 0628 115 0130 WASHER LOCK 850 0045 850 0060 SCREW HEXCAP 800 0503 C Specs P through T Includes Oil Line Begi...
Page 60: ...to Crankshaft FLYWHEEL Includes Ring Gearand Hub Assembly SPEC R AND S 134 1406 1 Standard 134 1556 1 With Optional Flywheel Alternator REF PART QTY PART NO NO USED DESCRIPTION 12 134 1401 1 Hub Flyw...
Page 61: ...130 2 Standard 113 0130 05 2 005 Oversize 113 0130 10 2 010 Oversize 11 3 0130 20 2 020 Oversize 113 0130 30 2 030 Oversize 113 0130 40 2 040 Oversize 2 PISTON AND PIN Includes Retaining Rings 112 010...
Page 62: ...ll Governor Shaft Thrust 5 16 10 509 0087 1 Seal Oil 11 103 0251 1 Gasket Gear Cover REF PART QTY PART NO NO USED DESCRIPTION 12 103 0218 1 Gasket Backplate 13 103 0271 1 Backplate Gear Cover 14 103 0...
Page 63: ...AIR CLEANER AND FUEL FILTERS 967 0423 JUNE 1979 6 2...
Page 64: ...12 1 4 336 1505 1 2 Cylinder 5 1 4 336 1346 1 Lead Air Heater to Solenoid in Control 140 0594 520 0621 865 0020 20 154 0712 21 REF PART QTY PART NO NO USEC DESCRIPTION 23 149 0769 1 Plug Air Bleed Se...
Page 65: ...FUEL PUMP INJECTION SYSTEM AND EXHAUST 6 4 967 0423 JUNE 1979...
Page 66: ...ked 12 or M 147 0189 1 125 Marked 13 or N 147 0188 1 128 Marked 14 or P 147 0187 1 131 Marked 15 or R 147 0186 1 134 Marked 16 or S REF PART QTY PART NO NO USED DESCRIPTION 17 154 0633 1 Manifold Exha...
Page 67: ...E 2 Spec P 1 Begin Spec R 1 Elbow Injection Pump Lubrication Tee Begin Spec R 1 Valve Oil By Pass 1 27 PART DESCRIPTION Spring By Pass Valve Plug Pipe 1 8 Tee Injection Pump Lubrication Restricted Lin...
Page 68: ...191 0392 1 Cover Switch Plate 8 191 0388 1 Control Assembly 9 160 0711 2 Spring Weight 10 160 0806 1 Disc Thrust Plunger 11 160 0774 1 Plunger REF NO 12 13 1 14 PART NO QTY USED PART DESCRIPTION 160 0...
Page 69: ...5 518 0203 1 Ring Snap Spring Retaining 6 336 0706 1 Lead Solenoid Ground 7 306 0242 1 Screw Solenoid Adjusting 8 86 2 0001 i Nut Hex 1 4 20 9 518 0218 Ring Retaining Spec P 10 306 0193 1 Cover Soleno...
Page 70: ...er 12 191 0712 1 Armature 13 191 0432 1 Clutch 14 191 1023 1 Head Assembly Commutator End REF NO PART NO QTY USED 15 191 1024 16 191 1025 17 191 1020 18 191 1026 19 191 0497 20 191 1027 21 191 1028 22...
Page 71: ...GOVERNOR AND THROTTLE CONTROL 8 H VARIABLE SPEED GOVERNOR a OPTIONAL CONSTANT SPEED GOVERNOR TWO SPEED GOVERNOR OPTIONAL 7 0...
Page 72: ...peed Governor with Manual Control at Engine Optional 16 153 0014 1 Nut Cable Variable Speed Governor with Cable Control Optional 17 810 0074 1 Screw Cable Variable Speed Governor with Cable Control Op...
Page 73: ...anel 134 1180 1 Washer Screw Retainer Door Panel Also 8 Used on Cover on Earlier Models REF PART QTY PART NO NO USED DESCRIPTION 10 870 0194 5 Nut Tinneman Door Panel and Cover 11 134 1088 1 Support B...
Page 74: ...ommet Rubber 191 0724 1 Stator Begin Spec V 305 0478 1 Regulator Voltage Begin Spec V 321 0165 1 Holder Fuse Begin Spec V 323 0488 4 Socket Connector Begin Spec V REF PART QTY PART NO NO USED DESCRIPT...
Page 75: ...Machine Round Head 7 134 1606 1 Rod Shutter Control Upper 10 32 x 5 16 8 134 1607 1 Rod Shutter Control Lower 28 821 0010 4 Screw Cap Hex Head 9 134 2900 4 Bearing Shutter Locking 1 4 20 x 1 2 10 134...
Page 76: ...134 1242 3 Bracket and Pivot Shutter 3 134 1238 1 Bracket Shaft and Pin Shutter 4 134 1252 2 Shutter Air Outlet 5 150 0998 1 Joint Ball 6 134 1247 1 Rod Shutter Control 7 134 1248 4 Bearing Air Shutte...
Page 77: ...es with Oil Pressure Switch 1 Light Pilot Red Engines with Charging Alternator 1 Lamp Pilot Ught Engines with Charging Alternator 6 J SERVICE KITS AND MISCELLANEOUS REF NO PART NO 98 1100 168 0086 522...
Page 78: ...imensions given are Inside Diameter ID Outside Diameter OD and Thickness Thk SPRING LOCK FLAT BOLT AND SCREW TYPES CARRIAGE BOLT TRUSS HEAD BINDER HEAD PAN HEAD HEXAGON HEAD FILLISTER HEAD FLATHEAD RO...
Page 79: ...ma li0 j i l r ONAN1400 73RD AVENUE ALE MINNEAPOLIS MINNESOTA 55432 1...
