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Cummins/Onan JC Engine

The Cummins/Onan JC is a air cooled engine rated at 1800 rpm. It powers generator sets from Cummins/Onan, including the 10.0JC, 12.5JC and 15.0JC.

Also known as: Onan JC

1800 rpm
Rated speed

Engine specifications

AspirationAir cooled
Rated speed1800 rpm

Troubleshooting

23

Symptoms & remedies

SymptomCauseRemedy
Generator Set Does Not Stop When Switch Is Pushed To Stop1a. Defective Start / Stop / Test switch (S11).<br>1b. Defective relay (K14).1 a. Test Start / Stop / Test switch and wiring.<br>1 b. Test relay K14 and wiring.
No AC Output Voltage1. The line circuit breaker is OFF.<br>2. The line circuit breaker has TRIPPED.<br>3. The line circuit breaker is faulty.<br>4. Reid circuit breaker CB21 has TRIPPED.1. Rnd out why the circuit breaker was turned OFF, make sure it is safe to reconnect power, and then throw the circuit breaker ON.<br>2. Shut down the set and service as necessary to dear the short drcuit or ground fault that caused tripping, and then RESET the drcuit breaker and start the set.<br>3. Shut down the set, make sure the power output lines from the set have been disconnected from all other sources of power, attempt to RESET the drcuit breaker and throw it ON and check for electrical continuity across each line contact. Replace the drcuit breaker if there is measurable resistance across any contact.<br>4. RESET the drcuit breaker. If it keeps tripping, troubleshoot according to Trouble heading.
Field Circuit Breaker Keeps Tripping5. Field circuit breaker CB21 is faulty.<br>6. The field has lost its residual magnetism.<br>7. The generator is faulty.5. Shut down the set, attempt to RESET the drcuit breaker and disconnect either lead. Replace the drcuit breaker if there is measurable resistance across the terminals.<br>6. If reference voltage across TB21-1 & 2 is not 20VAC or more, flash the field according to Servicing the Generator in Section 5.<br>7. Disconnect stator leads 1 & 2 from TB21 -1 & 2. Reference voltage across leads must be 20 VAC or more. If not, troubleshoot according to Trouble heading, Field Circuit Breaker Keeps Tripping.
Output Voltage Is Too High Or Too Low1. Engine speed is too high or too low.<br>2. The voltage has been adjusted improperly.<br>3. Improper connections have been made at the generator output terminals.<br>4. The rotating rectifier assembly (diodes CR1 through CR6) is faulty.<br>5. Defective reference transformer T21.<br>6. Voltage Regulator VR21 is faulty.1 a. Adjust engine speed according to engine service manual.<br>1b. If engine speed is unstable, troubleshoot according to Table 4-2, Control Troubleshooting - Run Mode.<br>2. Adjust output voltage according to AC Control in Section 2.<br>3. Shut down the set and reconnect according to the appropriate reconnection diagram (Page 7-7).<br>4. Shut down the set and check each diode according to Servicing the Generator in Section 5. Service as necessary.<br>5. Shut down the set and check T21 winding resistances according to Servicing the Generator in Section 5.<br>6. Replace the voltage regulator.
Engine Does Not Crank.1. Fuse FI on the control panel is blown. 2. Insufficient battery voltage due to: a. Batteries not charged. b. Battery connections loose or dirty. c. Insufficient battery charging voltage. 3. Start solenoid (K11) not energized due to: a. Defective Start / Stop / Test switch (S11). b. Defective solenoid (K11). 4. Starter (B1) not energized due to: a. Open circuit between battery (B+) and start solenoid (BAT). b. Defective starter (B1).1. Replace the fuse with one of the same type and amp rating. If fuse FI blows again, refer to wiring diagram in Section 7 to locate short or defective component. 2a. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C). 2b. Clean and tighten or replace the battery cable connectors and cables at the battery and the set. 2c. Adjust charge rate of battery charging circuit. Refer to Battery Charge Rate Adjustment in Section 6. 3a. Test Start / Stop / Test switch and wiring. 3b. Test solenoid K11 and wiring. 4a. Check wiring continuity between battery (B+) and the start solenoid contact (BAT). 4b. Test starter, see engine service manual.
Engine Cranks But Does Not Start.1. Restricted fuel supply due to: a. Closed shutoff valve in supply line. b. Engine is not getting fuel. 2. The engine ignition system is malfunctioning (ignition coil, distributor, spark plugs, high tension spark plug and coil cables and timing). 3. Run relay (K12) not energized due to: a. Defective start solenoid (K11). b. Defective run relay (K12). 4. Optional fuel solenoid (K1) not energized due to: a. Open in fuel solenoid circuit. b. Defective fuel solenoid. 5. Optional fuel tank solenoid (K2) not energized due to: a. Open in fuel tank solenoid circuit. b. Defective fuel tank solenoid.1a. Open any closed shutoff valve in the fuel line supplying the engine. 1b. Fill the main fuel supply tank if the set is gasoline or propane fueled, for natural gas fueled sets, check with the gas utility. 2. Service according to the engine service manual. 3a. Test solenoid K11 and wiring. 3b. Test run relay K12 and wiring. 4a. Check wiring continuity of fuel solenoid circuit. 4b. Test fuel solenoid. 5a. Check wiring continuity of fuel tank solenoid circuit. 5b. Test fuel tank solenoid.
Cranking Voltage Is Too Low To Reach Required Cranking Speed.While cranking the engine, measure voltage directly across the battery terminals and then immediately across the starter motor terminal and the grounding bolt on the block. Cable, terminal or relay contact resistance is too high if the difference is more than 1 volt. Service as necessary. Recharge or replace the battery. Specific gravity for a fully charged battery is approximately 1.260 at 80° F (27° C).
Fuel Pump Is Malfunctioning.The fuel pump (gasoline-fueled sets) is malfunctioning.Replace or service the fuel pump according to the engine service manual.
Carburetor Fuel Passages Are Clogged Or The Choke Needs Adjustment (Gasoline-Fueled Sets).The carburetor fuel passages are clogged or the choke needs adjustment (gasoline-fueled sets).Clean and rebuild gasoline carburetors with the appropriate carburetor kit according to the kit instructions. Adjust fuel mixture according to the engine service manual. Refer to Section 6, Adjustments, to service the automatic choke.
Engine Starts, but Stops When Start Switch is Released1. Centrifugal switch (SI) faulty or out of adjustment. 2. Defective fault sensor switch (low oil pressure, high air temp., or overspeed switch). 3. Open or defective fault circuit breaker (CB4, CB5, or CB6). 4. Diode CR12 defective.1. Refer to Section 6, Adjustments. 2. Refer to engine service manual. 3. Check breakers. If open, locate and correct cause of fault. 4. A good diode has a higher reading in one direction than the other, if both readings are high, or low, diode is defective.
Engine Starts, but Lacks Power or Stops1. Fuel delivery to the set is inadequate. 2. Fuel is contaminated. 3. Dirty air filter. 4. The governor and carburetor fuel mixture adjustments are incorrect. 5. Gaseous fuel delivery (vapor withdrawal) to the set is inadequate.1 a. Check for and replace clogged fuel lines and filters. 1 b. Measure the vertical distance between the fuel lift pump on the engine and the bottom of the dip tube in the supply tank. Make necessary provisions so that lift does not exceed 6 feet (1.8 metres). 2. Connect the set to a container of fuel of known quality and run the set under various loads. Replace the contents of the fuel supply tank if there is a noticeable improvement in performance. 3. Check air filter and dean if dirty. 4. Adjust the carburetor fuel mixture according to the engine service manual. Refer to Section 6, Adjustments, to service the automatic choke. 5. Check the gas supply pressure at the fuel inlet fitting on the skid. Make necessary provisions so that gas supply pressure is at least 10 inches (254 mm) Water Column (WC) when the set is under full load, and not more than 20 inches (508 mm) WC.
Fault Shutdown Occurs, but No Fault Lamp IndicationPerform lamp test by engaging Alarm Test switch. All lamps should light. Replace defective lamp.
Fault Lamp Illuminated: a. Overspeed b. Low Oil Pressure c. High Engine TemperatureA. Refer to Section 6, Adjustments, to verify operation of overspeed switch (S5). b. Check oil level and add oil if low. Monitor oil pressure gauge. If gauge reading is within normal range, switch S4 is defective. If oil pressure is low, stop engine immediately. Refer to engine service manual. c. Check air inlet to make sure it is open and free of debris. Refer to engine service manual to verify operation of high engine temp switch (S6).
No Fault ConditionCheck condition of all control wiring to ensure correct and secure terminal connections.
Low Battery Voltage1. Weak or discharged battery due to: a. Low charge rate. b. Low electrolyte level in battery. c. Long periods of non-use. d. Improperly wired battery.1 a. Adjust slide tap on adjustable resistor R21 for proper charge rate. Refer to Battery Charge Rate Adjustment in Section 6. 1 b. Replenish electrolyte and recharge battery. 1 c. Connect a separate battery charger to bring battery up to full charge. 1 d. Reconnect and check battery connection.
Generator Set Charging Circuit Not Functioning2a. Open in circuit between generator B1-B2 winding and battery (B+). 2b. Open charging resistor (R21). 2c. Diode CR21 defective. 2d. Generator B1-B2 defective.Check all wiring connections between the generator B1-B2 windings and the battery B+ connections, including all connections to the diode CR21 and battery charge resistor (R1). Remove wires from the charge resistor (R21) and measure its resistance. A normal reading
The engine will not crank.Possible fault with control or starting system.Check for the following conditions: a. Fuse F1 has blown. Replace the fuse with one of the same type and amp rating. b. Fault circuit breaker has tripped. Service the fault, and reset the circuit breaker. c. Poor battery cable connections. Clean the battery
Indicates insufficient battery voltageBatteries not charged. Battery connections loose or dirty. Insufficient battery charging voltage (contact an Onan distributor for assistance).Contact an Onan distributor for assistance.
The engine cranks, but does not start or starts and then shuts down.Check for empty fuel tank, fuel leaks, or plugged fuel lines and correct as required. Check for dirty fuel filter and replace if necessary (see Maintenance section). Check for dirty or plugged air filter and replace if necessary (see Maintenance section). Check ignition system (see Maintenance section). Contact an Onan distributor for assistance if none of the above.
Engine runs and then shuts downEngine has exceeded normal operating speed.Contact an Onan distributor for service.
Fault lamp lights but no fault exists. Engine gauges show oil pressure.Engine sensor is faulty. Contact an Onan distributor for assistance.
Fault lamp(s) does not lightReplace defective lamp(s).
No AC output voltage because the line circuit breaker (if provided) or the field circuit breaker has tripped.Determine the cause (overload or short circuit) and clear the fault. Reset the line circuit breaker and/or the field circuit breaker. Contact an Onan distributor if voltage buildup causes breaker to trip.

Fault codes and symptom→remedy steps extracted from this engine’s service/owner documentation; verify against the official manual before servicing.

Common problems

15
  • Partial loss of residual in rotor.
    Fix: With plant operating, jumper from E2 to heat sink of field rectifier Z until voltage begins to build up. Then remove.
  • Pair of field rectifiers open (either W and Z or X and Y).
    Fix: Test rectifiers and replace if defective.
  • Over-Voltage or Fluctuating Voltage
    Fix: If the engine is operating at the correct speed, see Magneciter Troubleshooting Chart.
  • Output voltage slow to build up.
    Cause: Either field rectifier X or Y shorted.
    Fix: Test rectifiers and replace if defective.
  • Output voltage slow to build up and higher than rated voltage after build up.
    Cause: Open circuit in one or more control rectifier.
    Fix: Test rectifiers and replace if defective. Check soldered connections to rectifiers.
  • Output voltage slow to build up and 10 to 20 percent above rated voltage after build up.
    Cause: Open circuit in one field rectifier.
    Fix: Test rectifiers and replace if defective.
  • Output voltage builds up normally with slightly less than rated voltage at no load and 20 percent above rated voltage at full load.
    Cause: Compound winding S1-S2 in- stalled backward or has open circuit through one of compound windings through reactors A and B and test for continuity.
  • Output voltage builds up normally but less than rated voltage at no load and low voltage at full load.
    Cause: Shorted winding in control reactor.
    Fix: Test control reactor and replace if defective.
  • Output voltage builds up normally but is 125 to 150 percent above rated voltage after build up.
    Cause: Shorted turn in gate winding Gi-G2 of reactor A or B.
    Fix: Test reactors A and B for shorted turns and replace if defective.
  • Output voltage builds up normally but 25 percent above rated voltage after build up: No regulation possible.
    Cause: Open circuit in control rectifier bridge.
  • Output voltage builds up normally but 150 to 200 percent above rated voltage after build up. No regulation possible.
    Cause: Shorted turn in control winding C1-C2 or reactor A or B.
    Fix: Check circuit connections of both reactors A and B.
  • Output voltage builds up normally but 150 to 200 percent above rated voltage after build up.
    Cause: Control winding C1-C2 or reactor A or B polarized incorrectly.
    Fix: Check circuit connections of both reactors A and B.
  • Open in circuit breaker.
    Fix: Stop plant and check breaker continuity.
  • No Voltage Buildup
    Fix: Remove the exciter cover and with the plant tuning, operate the residual reset button on the Magneciter. If output voltage won’t build up after pushing the reset button, flash the field.
  • No AC power to Magneciter.
    Fix: Check AC voltage at E1-E2 with the plant operating, should be 5 percent of the rated voltage. If not, check continuity from EyEa back to generator.

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

Service intervals

40
ItemActionHoursMonthsNotes
Exhaust systemInspect8 hrDaily
Fuel supplyCheck8 hr
Generator setInspect8 hrDaily
Inspect plant generallyInspect8 hrPeriodic Service Guide
Oil levelCheck8 hr
Air cleanerCheck50 hr
BatteryCheck50 hrCheck condition of the battery
Crankcase oilChange100 hrFirst service — Change crankcase oil after the first 50 hours
Cylinder head boltsAdjust50 hrFirst service — After the first 50 hours of operation, retighten the cylinder head bolts
Cylinder head bolts and valve clearanceAdjust50 hrFirst service — After first 50 hours on a new or overhauled engine
Air cleanerOther100 hrService more often under extreme dust conditions
Air cleaner (dry paper cartridge)Clean100 hrDo not wash; replace at least every 500 hours
Battery water level and charge conditionCheck100 hr
Fuel filterClean100 hrFuel filter sediment bowl
Governor linkageCheck100 hr
Governor linkageClean100 hrClean and adjust (governor rod ball joints)
Air cleaner (foam element)Clean200 hrReplace only if damaged
Battery electrolyte levelCheck200 hr
Breaker pointsCheck200 hr
Crankcase breatherClean200 hr
Crankcase breatherReplace200 hrSeries JB
Fuel sediment bowlDrain200 hrEmpty fuel sediment bowl
GeneratorClean1000 hrClean the generator
Ignition breaker pointsAdjust200 hrSeries JC; clean and adjust
Oil filterReplace200 hrNormally every 200 hours; shorten if oil very dirty
Spark plugCheck200 hrCheck the spark plug gap
Breather baffleClean500 hr
Build-up relay (02SX exciters)Clean500 hr02SX exciters require build-up relay cleaning
Generator brushesInspect500 hr
PCV valveClean500 hrSeries JC
PCV valve (JC begin Spec T)Clean500 hrWash in diesel fuel or kerosene
Starter disconnect breakerReplace500 hrService the starter disconnect breaker
Valve clearanceCheck500 hrFirst service — Tighten head bolts and adjust valve clearance after first 50 hours on a new or overhauled engine
Voltage build-up relay (02SX exciters)Clean500 hrJ-series generator sets using 02SX exciters
Ball bearingInspect1000 hrInspect every 1000 hours with the plant running
BrushesInspect1000 hrRevolving field generator
Collector ringsInspect1000 hr
Cooling fins (cylinder block and heads)Clean1000 hrMore often under dirty conditions
ExciterInspect1000 hrPeriodic inspection of the exciter
Exciter, ball-bearing, collector rings, brushesInspect1000 hrat least every 1000 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
ClearanceArmature runoutless than .002in.
ClearanceBrush wear limit5/16inchreplace when worn to this
ClearanceCam Tappet Diameter (Begin Spec P).8725 - .8730in
ClearanceCam Tappet Diameter (Prior to Spec P).7475 - .7480in
ClearanceCam Tappet Hole Diameter (Begin Spec P).8755 - .8765in
ClearanceCam Tappet Hole Diameter (Prior to Spec P).7505 - .7515in
ClearanceCamshaft Bearing Clearance Limit.0012 - .0037in
ClearanceCamshaft End Play.007 - .039in
ClearanceCamshaft to bearing clearance.0012 to .0037in.
ClearanceCollector rings T.I.R..002inch
ClearanceCollector rings Total Indicated Reading (T.I.R.).002in.
ClearanceConnecting Rod Bearing-to-Crankshaft Clearance.001 - .003in
ClearanceConnecting Rod Bushing Clearance.0002 - .0007in
ClearanceConnecting Rod Journal Diameter2.0600 - 2.0605in
ClearanceConnecting Rod Large Bore Diameter2.1871 - 2.1876in
ClearanceConnecting Rod Small Bore Diameter1.044 - 1.045in
ClearanceConnecting rod bearing to crankshaft journal clearance.001 to .003in.
ClearanceConnecting rod upper bushing to piston pin clearance.0002 to .0007in.
ClearanceCrankshaft End Play.010 - .015in
ClearanceCrankshaft Main Bearing Journal Diameter2.2430 - 2.2435in
ClearanceCrankshaft Main Bearing Journal Diameter2.2440 - 2.2445in
ClearanceCrankshaft end play.010 to .015in.
ClearanceCrosshead to valve spring retainer.025inchminimum
ClearanceCylinder Bore3.250in
ClearanceDistributor shaft side playless than .005in5 lb pull
ClearanceExhaust Valve Guide Clearance.0030 - .0050in
ClearanceFuel pump coupling buffer end clearance1/16inchminimum
ClearanceFuel pump drive coupling alignment.010inchat 4 equidistant points on pump spider
ClearanceIntake Valve Guide Clearance.001 - .003in
ClearanceIntake Valve Stem Diameter.3405 - .3415in
ClearanceMain Bearing Clearance.0014 - .0052in
ClearanceMain Bearing Clearance.0024 - .0052in
ClearancePiston Clearance to Cylinder Wall (90 deg to pin, just below oil ring groove).0012 - .0032in
ClearancePiston PinThumb Push Fit
ClearancePiston Ring Width, 2nd.0925 - .0935in
ClearancePiston Ring Width, 3rd.1860 - .1865in
ClearancePiston Ring Width, Top.0925 - .0935in
ClearancePiston clearance (90 deg from piston pin axis, 3/8 in. below oil control ring).0012 - .0032in.
ClearanceStarter armature end play.005 - .030in
ClearanceStarter pinion clearance.09 +/- .02intarget .07
GapBelt deflectionequal to thickness of belt for each foot of free spanapprox 13 pounds index finger force
GapBreaker Point Gap.020in
GapCentrifugal switch contact gap.020in.
GapCentrifugal switch point gap0.040inches
GapDistributor breaker point gap.018 - .022inmaximum gap
GapIgnition breaker point gap.020inJB
GapIgnition breaker point gap0.018-0.022in (0.46-0.58 mm)
GapIgnition breaker point gap0.019-0.021in (0.48-0.53 mm)
GapMagneto Pole Shoe Gap.020in
GapMagneto pole shoe gap.025in
GapPiston Ring Gap.010 - .020in
GapPiston ring end gap.010 to .020in.
GapSpark Plug Gap.025in
GapSpark plug gap0.025in (0.64 mm)
GapSpark plug gap0.035in (0.89 mm)
GapStart-disconnect breaker point gap.020in
GapStarter disconnect breaker point gap0.020in (0.51 mm)
OtherBattery specific gravity when 75 percent charged1.290 to 1.22575 percent charged
OtherCenter pin extension from camshaft gear25/32in.
OtherCompression, standard new engine cranking at about 300 rpmabout 110psi

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
CoolantClean water, slightly alkalinepH value range of 8.5 to 10.5100.0 Keep chromate concentration between 100 and 150 grains per gallon; water should be free of chlorides, sulphates and acids; summer treatment one ounce chromate compound per two or three gallons of water
Engine oilSAE 30API MS, MS/DG, or MS/DM heavy-duty detergent oilRecommended for 30 deg F and above
Engine oilSAE 50Squirt a small amount into the cylinder to check for piston blow-by during the compression test
Engine oilSAE 5WMil-L-10295below 0°CUse where temperatures are not above 0°F (value copied as printed in °F); may need one grade heavier in heavily loaded applications
Engine oilSAE 5W-20API MS, MS/DG, or MS/DM heavy-duty detergent oilRecommended for 30 deg F and below
Engine oilSAE viscosity grades per ambient temperature chart (10W-30, 10W-40, 20W-40, 20W-50, 30 shown on chart)API service classification SF or SF/CC; must have passed MS Sequence Tests (or ASTM G-IV Sequence Tests); do not use Service DS oil3.5 quartsIncludes 0.5 quarts (0.47 l) for the oil filter. Viscosity chart temperature range shown as -20 to 100 F.
Engine oilSAE-30WMil-L-2104-A and/or British Defense Spec. DEF-2101B; Supplement I; Mil-L-2104-B; Series 3 (Mil-L-45199)Recommended for normal conditions and where sulphur content of diesel fuel is 0.5% to 1% by weight; SAE 20W Series 3 premium oils not required except unusual conditions
Engine oilSAE 10W-10°C to 30°CTemperatures consistently between -10°F and 30°F (units copied as printed)
Engine oilSAE 2020°C to 90°CTemperatures consistently between 20°F and 90°F (units copied as printed)
FuelGasoline/propane/natural gasHigh compression pistons are necessary for full rated output on natural gas.
FuelNeutral distillate petroleum oilViscosity 2.4 to 5.0 centistokes (34 to 42 Saybolt Universal) @ 100°F; Gravity 30 to 42 degrees A.P.I. at 60°F; Cetane Number 40 minimum; Sulphur not to exceed 1% by weightPour point 10°F below lowest expected temperature; bottom sediment and water not to exceed .05% by weight; free from suspended matter
FuelRegular grade gasolinePremium fuels contain more tetra ethyl lead; change stored fuel each season to keep fresh
GreaseMulti-purpose industrial greaseASTM Penetration, Normal Worked 285 to 320; Dropping Point 325°F; Water 1% maximumDo not mix grades or brands; excessive lubrication is as harmful as inadequate lubrication
OtherLubricating graphite or light non-gumming oilFor periodic lubrication of governor linkage

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 Injectors and Valves adjustment

⚠ Injectors must always be adjusted before valves.

⚠ Be careful not to bruise injector tip.

Tools: Inch-pound torque wrench (Snap-On Model TQ12B or equivalent), Screwdriver adapter, Feeler gauge, Wire gauge

  1. If used, pull compression release lever back and block open.
  2. Bar engine in direction of rotation until No. 1 VS mark appears.
  3. Adjust injector plunger, then crossheads and valves of first cylinder.
  4. Turn crankshaft to next VS mark per firing order; adjust that cylinder.
  5. Continue until all injectors and valves are adjusted.
  6. Injector plungers adjusted with inch-pound torque wrench to torque setting.
  7. Warm engine to 140°F oil temperature and reset injectors to warm setting.
  8. Always make final valve adjustment after injectors and with engine at operating temperature.
Adjust air shutter (Vernatherm element) adjustment

⚠ Air housing door must be on when operating engine

Tools: Screwdriver

  1. Loosen power element mounting screws in slotted holes
  2. Slide assembly until plunger rests on roll pin with shutter closed
  3. Shutter must be closed at ambient temperature
  4. Test element by heating: plunger moves out at about 120F
  5. Total plunger movement should be at least 13/64 in
Adjust gasoline carburetor adjustment

⚠ Do not force needle valves against seats

Tools: Screwdriver

  1. Allow engine to warm up
  2. At no load turn idle adjustment out until speed drops slightly
  3. Turn needle in until speed returns to normal
  4. Apply full load, turn main adjustment in until speed drops
  5. Turn needle out until speed returns to normal
Adjust governor speed and sensitivity adjustment

⚠ Oversensitive adjustment may cause hunting

Tools: Reed frequency meter, Wrench

  1. Hold governor spring stud, turn nut to set speed
  2. Use a reed type frequency meter on generator AC output
  3. Prior Spec R: turn spring stud counterclockwise for more sensitivity
  4. Adjust for maximum sensitivity without hunting
  5. Begin Spec R: turn speed nut clockwise to increase speed
  6. Begin Spec R: turn ratchet nut counterclockwise to increase spring tension
Adjust valve clearance (four-cylinder) adjustment

Tools: Feeler gauge

  1. Adjust valves in firing order 1-2-4-3
  2. Set timing and clearance for cylinder 1
  3. Turn flywheel 180 degrees for cyl 2, between 10 and 45 deg past BC
  4. Adjust cylinder 2 clearance
  5. Turn 180 degrees for cyl 4, between 10 and 45 deg past TC, adjust
  6. Turn 180 degrees for cyl 3, between 10 and 45 deg past BC, adjust
Adjust valve clearance (two-cylinder) adjustment

⚠ Set clearances at room temperature, at least two hours after shutdown

Tools: Feeler gauge, Torque wrench

  1. Turn flywheel to compression stroke after intake valve closes
  2. Align TC mark with timing pointer, then turn clockwise 10 to 45 degrees
  3. Check cylinder head bolt torque
  4. Check rocker-arm-to-valve clearance with feeler gauge
  5. Adjust with locknut to Table 3 clearance
Adjust valve clearance - Four-Cylinder J-Series engines adjustment

⚠ Early model four-cylinder engines do not have a BC mark on the flywheel

Tools: feeler gauge

  1. Adjust valve clearance in firing order (1-2-4-3) sequence
  2. Set timing for number 1 cylinder and adjust the valve clearance
  3. Turn flywheel clockwise 180 degrees for number 2 cylinder (between 10 and 45 degrees past BC mark)
  4. Adjust valve clearance for number 2 cylinder
  5. Turn flywheel clockwise 180 degrees for number 4 cylinder (between 10 and 45 degrees past TC mark)
  6. Adjust valve clearance for number 4 cylinder
  7. Turn flywheel clockwise 180 degrees for number 3 cylinder (between 10 and 45 degrees past BC mark)
  8. Adjust valve clearance for number 3 cylinder
Adjust valve clearance - Two-Cylinder J-Series engines adjustment

Tools: feeler gauge, torque wrench

  1. Turn flywheel until cylinder to be adjusted is on its compression stroke
  2. Turn flywheel until TC mark lines up with timing pointer, then turn clockwise an additional 10 to 45 degrees
  3. Check cylinder head-bolt torque (see Fig. 60)
  4. Using a feeler gauge, check clearance between rocker arm and valve
  5. Increase or reduce clearance until proper gap is established, adjusting with the locknut
  6. Refer to Table 3 for correct valve clearance setting
Battery Charge Rate Adjustment adjustment

⚠ Avoid overcharging.

  1. Set slide tap on adjustable resistor R21 in generator air outlet to give about 2 amperes charging rate.
  2. If charge winding AC output is below 19 volts on 12 volt battery charge models, 38 volts on 24 volt models, 50 volts on 32 volt models, test charging circuit for opens or grounds.
  3. If a separate automatic demand control is used, adjust charge rate for maximum 4.5 amperes.
Check and Adjust Belt Tension adjustment

⚠ Never roll or tighten a belt over the pulley and never pry it on with a tool such as a screwdriver.

⚠ When two or more belts are used, they must be replaced as a set.

⚠ Do not tighten belt beyond figures given to eliminate belt squeak.

  1. Shorten distance between pulley centers so belt can be installed without force.
  2. Tighten belts so pressure of the index finger will depress belt to specified deflection.
  3. All new belts will loosen after running an hour or more and must be retensioned.
  4. If belt can be pushed down 1/8 inch more than recommended, retension.
  5. To clean a belt, wipe with approved belt lubricant or hydraulic brake fluid.
Gasoline Carburetor Adjustment adjustment

⚠ Do not force needle valves against their seats; this will bend the needle.

Tools: Screwdriver (adjusting needles)

  1. Be sure ignition and governor are adjusted and allow engine to warm up.
  2. With no generator load, turn idle adjustment out until speed drops slightly below normal, then in until speed returns to normal.
  3. Apply full load and carefully turn main adjustment in until speed drops slightly below normal, then out until speed returns to normal.
Governor Speed and Sensitivity Adjustment (Begin Spec R) adjustment

⚠ An over-sensitive adjustment may result in a hunting condition.

Tools: Wrench, Reed type frequency meter or mechanical tachometer

  1. Adjust engine speed by turning governor speed adjusting nut; clockwise increases speed, counterclockwise decreases.
  2. Adjust sensitivity by turning the sensitivity adjusting ratchet nut through hole in the blower housing.
  3. If speed drops too much at full load, turn ratchet nut counterclockwise to increase spring tension.
  4. After adjusting, replace dot button in blower housing and secure speed stud lock nut.

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
1101518V150 hertz
110/190353CV150 hertz
110/1903V150 Hz; decoded from Figure 3-4 (OCR degraded)
110/2201518V150 hertz
110/220153CV150 hertz
110/2201V150 Hz; decoded from Figure 3-4 (OCR degraded)
110/2203518V150 hertz
1151518V250 hertz
115/200353CV250 hertz
115/2301518V250 hertz
115/230153CV250 hertz
115/2301V250 Hz; decoded from Figure 3-4 (OCR degraded)
115/2303518V250 hertz
118/2003V450 Hz; decoded from Figure 3-4 (OCR degraded)
12013CV160 hertz
1201518V350 hertz
120singleM2-M412-lead reconnection table
120, 24012 wireRevolving armature; Specs A-S
120, 240single2-wireRevolving armature; Specs A-5
120, 240, 120/2401Reconnectible for 120, 240 or 120-240 Volts4 wireRevolving armature; Specs A-S
120, 240, 120/2401Revolving Field (3R) Reconnectible for 120, 240 or 120-240 Volt3 wireT2 must be grounded if field boost circuit is to work; any other ground may damage the exciter (negative ground only)
120, 240, 120/240single3R reconnectibleT1, T2, T4, 35Revolving field; terminal T2 must be grounded for field boost circuit; negative ground only
120, 240, 120/240singlereconnectibleM1, M2, M3, M4Revolving armature; Specs A-5
120-240threedelta wound 4-wire (5DR)Revolving field
120/20834 wireRevolving armature; Specs A-S
120/20833CV160 hertz
120/208353CV350 hertz
120/2083V160 Hz; decoded from Figure 3-4 (OCR degraded)
120/208three4-wire wyeRevolving armature or revolving field; Specs A-5
120/208, 277/480, 240/4163Revolving Field, Wye Wound, 4-wire, 3-Phase (-4R 120-208, -4XR 277-480, -57XR 240-416)4 wireT1 must be grounded if the field boost circuit is to work (negative ground only)

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

Which generators use the Cummins/Onan JC engine?

The Cummins/Onan JC powers 3 generator set(s), including Cummins/Onan 10.0JC, Cummins/Onan 12.5JC, Cummins/Onan 15.0JC.

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

A commonly reported issue on generators using the Cummins/Onan JC is: Partial loss of residual in rotor.. Fix: With plant operating, jumper from E2 to heat sink of field rectifier Z until voltage begins to build up. Then remove..