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Cummins/Onan DJA Engine

The Cummins/Onan DJA is a 0.49 L 1-cylinder air-cooled engine rated at 2400 rpm, producing up to 5.4 kW. It powers generator sets from Cummins/Onan and Onan (Onan Division of Studebaker Corporation, Minneapolis, Minnesota), including the 2.5DJA-51R, 2.5DJA-52R, 3.0DJA-1R and 3.0DJA-2R. It holds 2.4 L (0.6 gal) of oil.

Also known as: Onan DJA

0.49 L
Displacement
1
Cylinders
2400 rpm
Rated speed
5 kW
Gross power

Engine specifications

Oil capacity2.4 L
Displacement0.49 L
Cylinders1
AspirationAir-cooled
Rated speed2400 rpm
Gross power5 kW

Common problems

15
  • Engine losing speed momentarily or low engine power
    Cause: Dirty cooling surfaces, operating without the engine air housing, poor air circulation, improper lubrication, wrong injection timing and engine overload.
  • Worn or sticking piston rings EXCESSIVE OIL CONSUMPTION, LIGHT BLUE SMOKY EXHAUST
    Fix: Check compression. Clean or replace ring: a
  • Worn oil pump Low Oi PRESSURE
    Fix: Replace pump
  • Worn bearings Low Oi PRESSURE
    Fix: Rebuild engine
  • VOLTAGE DROPS UNDER HEAVY LOAD
    Cause: Engine lacks power, Poor compression, Faulty injection, Dirty air cleaner, Restricted exhaust line
    Fix: See remedies for engine misfires, Tighten cylinder head and glow plug. If still not corrected, grind the valves. Replace piston rings, if necessary., Check the fuel system. Clean, adjust or replace parts necessary, Clean
  • Unusual noises, loss of power, etc.
    Fix: Contact your ONAN dealer.
  • Unusual noises, loss of power
    Fix: Contact your Onan dealer
  • TAPPING SOUND
    Cause: Valve clearance too great, Broken valve spring
    Fix: Adjust. Replace faulty valve system, Install new spring
  • Sticking compression ring
    Fix: Replace
  • SHARP METALLIC THUD, ESPECIALLY WHEN COLD ENGINE FIRST STARTED
    Cause: Low oil supply, Oil badly diluted
    Fix: Add oil, Change oil
  • Overload 10
  • Overheating
    Cause: Dirty cooling surfaces, operating without the engine air housing, poor air circulation, improper lubrication, wrong injection timing and engine overload
  • Oil too heavy LOW OIL CONSUMPTION
    Fix: Replace with lighter oil
  • OIL SYSTEM
    Cause: [Diluted oil due to leaky fuel transfer pump diaphragm. Faulty cylinder oil control.
    Fix: Rebuild or replace pump if diaphragm is leaking. Inspect rings and cylinder walls for issues related to faulty cylinder oil control.
  • Oil supply low Low Oi PRESSURE
    Fix: Check cause: of oil consumption. Governor incorrectly adjusted.

Compiled from service & troubleshooting documentation across every generator set that uses the Cummins/Onan DJA.

Maintenance schedule

ItemSpecCapacityPart #Interval
Air filter140B64050 hr Amazon eBay
Fuel filter149C408500 hr Amazon eBay
Oil filter122A185200 hr Amazon eBay $18.80 NAPA $12.88
Battery—100 hr
Belt—500 hr
CoolantDrain water periodically from both filters and sediment bowl. Replace primary filter every 600 hours, secondary filter every 3000 hours.—600 hr
Coolant filter—
Oil2.5 quarts—500 hr
Spark plug—500 hr

Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.

Service intervals

40
ItemActionHoursMonthsNotes
EngineInspect8 hr
Engine oil levelCheck8 hrFirst service — During break-in, check at least every 8 operational hours
Exhaust systemInspect8 hr
Fuel supplyCheck8 hrSee Note 1
engine oilCheck8 hrCheck Oil Level (Operator Maintenance Schedule)
Air cleanerCheck50 hrWash filter element; replace if damaged
Air cleaner elementClean50 hrCheck after each 50 hours of operation
Battery conditionCheck50 hrSee Note 2
Crankcase oilChange100 hrFirst service — Drain and replace crankcase oil after first 50 hours; drain while engine is still hot
Cylinder head boltsAdjust50 hrFirst service — After first 50 hours of operation, retighten cylinder head bolts and check valve clearance
Cylinder head boltsCheck50 hrFirst service — Tighten head bolts and adjust valve clearance after first 50 hours on new or overhauled engine
Fuel Tank Water and SedimentDrain50 hrEvery 50 Service Hours or Weekly
Fuel condensation traps in lines and filtersDrain50 hrSee Note 1
Oil levelCheck50 hrSee Figure 2
Oil-wetted-foam type air cleanerClean50 hrWash in clean fuel; moisten with clean crankcase grade oil
Valve clearanceAdjust50 hrFirst service — After first 50 hours on new or overhauled engine
Governor LinkageClean100 hrEvery 100 hours; clean plastic joint only, steel joint with graphite
Oil filterReplace100 hr
Oil-bath type air cleanerClean100 hrThoroughly clean and put in fresh oil
Generator armature, ball bearing, collector rings, commutator, brushesInspect400 hrNormal maintenance procedure
Air cleaner cartridgeReplace500 hrInstall new cartridge at least every 500 hours
Battery Electrolyte LevelCheck500 hr12 moEvery 500 Service Hours or 1 Year
Breather standpipesClean500 hrCrankcase breather pipe must be cleaned after every 500 hours
Engine Air Cleaner Element (Dual Element)Clean500 hr12 moEvery 500 Service Hours or 1 Year - Clean/Replace
Engine Air Cleaner Element (Single Element)Inspect500 hr12 moEvery 500 Service Hours or 1 Year - Inspect/Replace
Engine GroundInspect500 hr12 moEvery 500 Service Hours or 1 Year - Inspect/Clean
Engine Oil and FilterChange500 hr12 moEvery 500 Service Hours or 1 Year
Fuel System Primary Filter (Water Separator) ElementReplace500 hr12 moEvery 500 Service Hours or 1 Year
Fuel System Secondary FilterReplace500 hr12 moEvery 500 Service Hours or 1 Year
Hoses and ClampsInspect500 hr12 moEvery 500 Service Hours or 1 Year - Inspect/Replace
RadiatorClean500 hr12 moEvery 500 Service Hours or 1 Year
Start-disconnect circuitCheck500 hr
Valve clearancesCheck500 hr
Primary fuel filterChange600 hr
primary fuel filterReplace600 hrReplace primary filter every 600 hours (Spec S and later)
Engine Valve LashInspect1000 hrEvery 1000 Service Hours - Inspect/Adjust
Engine cooling areaClean1000 hrMore often under dirty operating conditions
Engine cooling area (fins)Clean1000 hrNormally every 1000 hours, more often under dirty operating conditions
cooling finsClean1000 hrClean engine cooling area normally every 1000 hours, more often in dirty conditions
Aftercooler CoreInspect2000 hrEvery 2000 Service Hours

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

60
TypeItemValueUnitCondition
ClearanceBrush wear limit (replace)5/8in
ClearanceCam tappet hole diameter (prior to Spec P).7505-.7515inprior to Spec P
ClearanceCamshaft Bearing Clearance Limit0.0012-0.0037inchAt room temperature of 70 F
ClearanceCamshaft Bearing Journal Diameter, Front2.500-2.505inchAt room temperature of 70 F
ClearanceCamshaft Bearing Journal Diameter, Rear1.1875-1.1880inchAt room temperature of 70 F
ClearanceCamshaft bearing clearance limit.0012-.0037in
ClearanceCamshaft bearing journal diameter, front2.500 - 2.505in
ClearanceCamshaft bearing journal diameter, rear1.1875 - 1.1880in
ClearanceCamshaft end play.007 - .039in
ClearanceCamshaft end play.007-.039in
ClearanceCamshaft end play (new)0.10 to 0.55mm (0.004 to 0.022 inch)Maximum permissible end play of a worn camshaft 0.60 mm (0.023 inch)
ClearanceClearance between the bearing shell and the main bearing journals0.057 to 0.117mm (0.0022 to 0.0046 inch)
ClearanceClearance in cylinder (begin Spec P).0055-.0075in90 degrees to pin, just below oil ring
ClearanceClearance in cylinder (prior to Spec P).0050-.0070in90 degrees to pin, just below oil ring
ClearanceClearance in guide, exhaust valve0.0025-0.0045inch
ClearanceClearance in guide, intake valve0.0005-0.0025inch
ClearanceClearance, Large Bearing to Crankshaft0.001-0.003inch
ClearanceCollector ring run-out0.002incompared to generator bearing
ClearanceCommutator and slip ring run-out.002in.less than
ClearanceCommutator mica undercut1/32in.under the bars
ClearanceConnecting Rod Bushing Clearance0.0002-0.0007inch
ClearanceConnecting Rod Journal Diameter2.0597-2.0605inch
ClearanceConnecting Rod Large Bearing Bore Diameter2.1871-2.1876inch
ClearanceConnecting rod bearing clearance.001-.0033in
ClearanceConnecting rod bearing clearance0.030 to 0.081mm (0.0012 to 0.0032 inch)
ClearanceConnecting rod bushing clearance.0002-.0007in
ClearanceConnecting rod end play.002-.016in
ClearanceConnecting rod large bearing bore diameter (w/o bearing)2.1871-2.1878in
ClearanceConnecting rod small bushing bore diameter (w/o bushing)1.044-1.045in
ClearanceCrankshaft Main Bearing Clearance0.0014-0.0052inch
ClearanceCrankshaft Main Bearing Journal Diameter2.2437-2.2445inch
ClearanceCrankshaft connecting rod journal diameter2.0597-2.0605in
ClearanceCrankshaft end play.010-.018in
ClearanceCrankshaft end play0.010-0.015in
ClearanceCrankshaft main bearing journal diameter2.2487-2.2445in
ClearanceCylinder Diameter Limits3.2495-3.2505inchBore must be less than 0.001 inch out-of-round
ClearanceCylinder bore105.000 to 105.025mm (4.1338 to 4.1348 inch)
ClearanceCylinder bore limits3.2195-3.2505in
ClearanceCylinder head thickness117.95 to 118.05mm (4.643 to 4.647 inch)Minimum thickness 117.20 mm (4.614 inch)
ClearanceEnd Play, Camshaft0.007-0.039inchAt room temperature of 70 F
ClearanceEnd Play, Crankshaft0.010-0.015inch
ClearanceExhaust valve stem diameter.3405-.3415in
ClearanceGovernor cup center pin distance from camshaft gear25/32in
ClearanceIntake valve clearance in guide.0015-.0030in
ClearanceIntake valve stem diameter.3405-.3410in
ClearanceMain bearing clearance (original).002-.0033in
ClearanceMain bearing clearance (replacement).0014-.0052in
ClearanceMaximum permissible wear for the cylinder bore0 to 0.15mm (0 to 0.0059 inch)
ClearanceOriginal size of the connecting rod bearing journal63.47 to 63.49mm (2.4988 to 2.4996 inch)
ClearanceOriginal size of the main bearing journal76.159 to 76.180mm (2.9984 to 2.9992 inch)
ClearancePiston Clearance to Cylinder Wall0.0055-0.0075inchMeasured 90 degrees from piston pin axis below oil control ring
ClearancePiston clearance to cylinder wall.0050-.0070inprior to Spec P
ClearancePiston clearance to cylinder wall.0055-.0075inSpec P and later
ClearancePiston pin fitThumb Push Fitroom temperature
ClearancePiston ring groove width 2nd.0965-.0975in
ClearancePiston ring groove width 3rd.0965-.0975in
ClearancePiston ring groove width top.097-.098in
ClearanceRing gap.010-.020in
ClearanceRod bearing clearance.001-.0033in
ClearanceShim thickness.006 to .052in.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

FluidGradeStandardAmbientCapacityNotes
CoolantCommercial heavy-duty coolant/antifreezeASTM D4985Do not use coolant/antifreeze that only meets ASTM D3306. Perkins recommends 1:1 water/glycol, may be increased to 1:2 water to glycol
CoolantPerkins Extended Life Coolant (ELC) 1:1 water/glycol (premixed)Perkins ELC; freeze protection to -36 °C (-33 °F)ELC Concentrate lowers freezing point to -51 °C (-60 °F) for arctic conditions
CoolantPerkins Liquid SCA + water6 to 8 percent concentration of SCAPart number 21825755; for stationary and marine applications without anti-boil or freeze protection
CoolantantifreezeReplace annually in captive system
Coolant50 Percent Ethylene GlycolASTM D4985above -36°C50.0 PercentFreeze protection -36 °C (-33 °F), boil protection 106 °C (223 °F); 60 percent gives -51 °C (-60 °F) / 111 °C (232 °F)
Coolant50 Percent Propylene GlycolASTM D4985above -29°C50.0 PercentDo not use propylene glycol in concentrations that exceed 50 percent because of reduced heat transfer capability
Engine oilAPI CD/SE or CD/SD2.0 U.S. quarts2-1/2 U.S. quarts (2.4 litres); add 1/2 quart for oil filter
Engine oilAPI CD/SEDiesel engines; use CC/SE for first fill only (50 hours)
Engine oilAPI SE or SE/CCGasoline engines
Engine oilMulti-grade (such as 5W-30)API classification CC/SE (grades 10W-30, 10W-40 or 5W-30 only)below 0°CRecommended for service in ambient temperatures of 32 F and colder
Engine oilSAE 10W or 5W-200F to 30F
Engine oilSAE 10W or 5W-30API CD/SE or CD/SDFor 0 F to 30 F. Multigrade oils recommended at 30 F and below, not recommended above 30 F
Engine oilSAE 30API CD/SE or CD/SDFor temperatures above 30 F. CC oil for first fill only (50 hours) on new or rebuilt engine; add 1/2 quart for oil filter
Engine oilSAE 5W-20Below 0F
Engine oilSAE 5W-30API CD/SE or CD/SDFor temperatures below 0 F
Engine oilsame SAE number as is in the crankcaseUsed in optional oil bath air cleaner cup; do not overfill
Engine oilSAE 0W20EMA LRG-1 / API CH-4-40°C to 10°C
Engine oilSAE 0W30EMA LRG-1 / API CH-4-40°C to 30°C
Engine oilSAE 0W40EMA LRG-1 / API CH-4-40°C to 40°C
Engine oilSAE 5W30EMA LRG-1 / API CH-4-30°C to 30°C
Engine oilSAE 5W40EMA LRG-1 / API CH-4-30°C to 40°C
Engine oilSAE 10W30EMA LRG-1 / API CH-4-20°C to 40°C
Engine oilSAE 15W-40 or 20W-40-10°C to 32°CJ-series water-cooled diesel engines
Engine oilSAE 15W40EMA LRG-1 / API CH-4-10°C to 50°CPreferred oils: EMA DHD-1 multigrade, API CH-4 multigrade, ACEA E3. Minimum TBN of new oil = 10 times fuel sulfur level, minimum 5.
FuelASTM 2-D or 1-Dminimum Cetane number of 45Use 1-D fuel when ambient temperatures are below 32 F or during long periods of light/no load. Low sulfur fuel with pour point at least 10 F below lowest expected temperature
FuelASTM 2-D or 1-D diesel fuelmin. Cetane number 45; low sulfurNumber 2 diesel gives best economy; below 32 F (0 C) use Number 1 diesel fuel. Pour point at least 10 F below lowest expected temperature
FuelDiesel - Group 1 (preferred) DERV to EN590, Gas oil to BS2869 Class A2, ASTM D975-91 Class 2D, JIS K2204 (1992) Grades 1,2,3 and Special Grade 3Cetane number 45 minimum; Viscosity 2.0 to 4.5 cSt at 40 °C; Density 0.835 to 0.855 Kg/liter; Sulfur 0.2% of mass maximum; Distillation 85% at 350 °C; Lubricity 460 micrometers maximum wear scar on ISO 12156-1Group 2 (permissible) and Group 3 (aviation kerosene) also listed. Biofuel: a 5% mix of RME to EN14214 in conventional fuel is permitted. Water emulsion fuels are not permitted.
FuelNo. 1 dieselUse when ambient temperature below 32F, long periods of light load, or if preferred
FuelNo. 2 dieselBest economy
Fuellow sulfur contentpour point at least 10 degrees below lowest expected temperatureKeep fuel clean; leave room for expansion

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

12
Adjust Carburetor adjustment

⚠ Do not force needles against seats.

  1. Open both needles 1 to 1-1/2 turns off seats.
  2. Apply full load; turn main fuel screw in until speed drops, then out to normal.
  3. Remove load; turn idle screw out until speed drops, then in to normal.
Adjust Decompression Release adjustment

⚠ If the screw is tightened more than one turn, the exhaust valve could hit the piston

Tools: Feeler gauge

  1. Set valves for correct clearance first.
  2. Leave flywheel at 10 to 45 degrees ATC with piston on power stroke.
  3. Set arm in decompression position; turn setscrew until it just touches exhaust rocker arm.
  4. Turn the screw exactly one revolution clockwise.
  5. Hold setscrew and tighten lock nut 1/4 to 1/2 turn past finger tightness.
Adjust Governor Linkage (Diesel) adjustment
  1. Loosen locknuts on governor linkage, remove link at one ball joint.
  2. Position governor arm and fuel control arm fully forward.
  3. Adjust linkage so both ball joints fit without moving arms.
  4. Tighten locknuts.
  5. Release fuel solenoid plunger.
Adjust Governor Speed adjustment

Tools: Screwdriver

  1. Hold the sensitivity stud in place with a screwdriver.
  2. Change spring tension with the speed adjusting nut.
  3. More tension gives more speed.
  4. To adjust high speed of solenoid two-speed governors, change solenoid rod length.
Adjust Valve Clearance adjustment

⚠ Check valve clearance when the engine is at room temperature about 70 F

Tools: Feeler gauge, Socket wrench, Rocker arm wrench

  1. Turn the flywheel until the cylinder is on its compression stroke.
  2. Turn the flywheel clockwise an additional 10 to 45 degrees.
  3. Loosen the rocker arm locknut to increase clearance, tighten to reduce clearance.
  4. Check clearance with a feeler gauge between rocker arm and valve.
  5. Set clearance to 0.011 inch intake and 0.008 inch exhaust.
Adjust Valve Clearance (Diesel) adjustment

Tools: feeler gauge, socket wrench

  1. Turn flywheel to compression stroke for cylinder to adjust.
  2. Turn flywheel clockwise additional 10 to 45 degrees.
  3. Loosen locknut to increase clearance, tighten to reduce.
  4. Use feeler gauge to set proper gap.
  5. Adjust in firing order 1-2-4-3.
Adjust Valve Tappet (Gasoline) adjustment

Tools: feeler gauge, wrench

  1. Remove valve covers.
  2. Crank engine until intake valve opens and closes.
  3. Continue 1/4 turn until timing marks align.
  4. Turn adjusting screw to obtain correct clearance.
  5. Use flat feeler gauge between valve and valve rotator.
Adjust governor speed and sensitivity adjustment

Tools: Reed-type frequency meter, Mechanical tachometer

  1. Turn governor speed adjusting nut clockwise to increase speed.
  2. Turn counterclockwise to decrease speed.
  3. Turn sensitivity adjusting ratchet nut counterclockwise to increase spring tension.
  4. Adjust for maximum sensitivity without hunting.
  5. Secure speed stud lock nut after adjusting.
Adjust injection nozzle opening pressure adjustment

⚠ Do not try to adjust pressure without a testing fixture.

Tools: Nozzle tester

  1. Remove nozzle from engine.
  2. Remove cap nut over the adjusting screw.
  3. Install nozzle on static fuel nozzle testing fixture.
  4. Adjust opening pressure to 1,750 psi by turning adjusting screw.
  5. Clockwise increases pressure; counterclockwise decreases.
Adjust the Vernatherm power element adjustment
  1. Loosen the power element mounting screws.
  2. Slide the assembly until it touches the roll pin with shutter closed.
  3. Tighten the mounting screws.
Align brush rig to neutral position adjustment

Tools: Voltmeter

  1. Remove end cover and band for access.
  2. Start unit and apply full rated load.
  3. Allow unit to reach full operating temperature.
  4. Connect voltmeter across dc terminals.
  5. Loosen brush rig mounting screws and rotate rig for highest voltage at full load.
  6. Rotate rig one direction until voltmeter reading decreases; mark point.
  7. Repeat in other direction; halfway between marks is neutral position.
Battery Charge Rate Adjustment adjustment

⚠ Avoid overcharging.

Tools: DC ammeter

  1. Set slide tap on resistor R4 to about 2 amperes charging rate.
  2. For frequent starts, increase charge rate slightly until battery stays charged.
  3. Stop engine when readjusting to avoid shorts.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Voltage reconnection

VoltagePhaseConnectionLeadsNotes
12-lead broad range reconnectible alternator12 leadUser connects for required voltage and amperage
X1 to VR21-5X1for 50 Hertz
X1 to VR21-6X1for 60 Hertz
1101518V150 hertz
110/190353CV150 hertz
110/2201518V150 hertz
110/220153CV150 hertz
110/2203518V150 hertz
1151518V250 hertz
115/200353CV250 hertz
115/2301518V250 hertz
115/230153CV250 hertz
115/2303518V250 hertz
12012-wireReconnectible
12013CV160 hertz
1201518V350 hertz
120-volt AC/32-volt DCsingledual purpose plantDJA wiring diagram dual purpose plant; diagram 6100220 page 60
120/20833CV160 hertz
120/208353CV350 hertz
120/208 voltthree4 wireDJA revolving armature; diagram 610C187 page 59
120/24013-wireStandard connection for MCCK/MDJE/MDJC/MDJF
120/24013CV160 hertz. Connect X1 to VR21-5 for 50 hertz and X1 to VR21-6 for 60 hertz generators. Jumper W10 on VR21 must connect VR21-V4 to V1, V2, or V3 as listed.
120/2401518V350 hertz
120/240153CV350 hertz
120/24033CV160 hertz
120/240 voltsingle3 wireDJA revolving armature; diagram 6100181 page 56
127/22033CV260 hertz
127/220353CV450 hertz
139/24033CV460 hertz
220/3803518V150 hertz

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

What is the oil capacity of the Cummins/Onan DJA?

The Cummins/Onan DJA engine has an oil capacity of 2.4 liters.

What is the displacement of the Cummins/Onan DJA?

The Cummins/Onan DJA has a displacement of 0.49 liters with 1 cylinders.

Which generators use the Cummins/Onan DJA engine?

The Cummins/Onan DJA powers 6 generator set(s), including Cummins/Onan 2.5DJA-51R, Cummins/Onan 2.5DJA-52R, Cummins/Onan 3.0DJA-1R, Cummins/Onan 3.0DJA-2R, Cummins/Onan 4.0DJA-FJ.

How often should you change the oil in the Cummins/Onan DJA?

The Cummins/Onan DJA oil change interval is every 500 hours.

What is a common problem with the Cummins/Onan DJA engine?

A commonly reported issue on generators using the Cummins/Onan DJA is: Engine losing speed momentarily or low engine power. Cause: Dirty cooling surfaces, operating without the engine air housing, poor air circulation, improper lubrication, wrong injection timing and engine overload..