HomeEnginesCummins/Onan RDJC

Cummins/Onan RDJC Engine

The Cummins/Onan RDJC is a 120 L 4-cylinder engine rated at 1800 rpm. It powers generator sets from Cummins/Onan, including the 12.5RDJC-518R, 12.5RDJC-53CR, 12.5RDJC-57R and 15.0RDJC-18R. It holds 6 L (1.6 gal) of oil and 12 L (3.2 gal) of coolant.

Also known as: Onan RDJC

Part of the Cummins/Onan RDJC engine family — 2 variants share parts & fitment.

120.0 L
Displacement
4
Cylinders
1800 rpm
Rated speed
6.0 L
Oil capacity

Engine specifications

Oil capacity6.0 L
Coolant capacity12.0 L
Displacement120.0 L
Cylinders4
Rated speed1800 rpm

Generator sets powered by this engine

9
Cummins/Onan 12.5RDJC-518RCummins/Onan 12.5RDJC-53CRCummins/Onan 12.5RDJC-57RCummins/Onan 15.0RDJC-18RCummins/Onan 15.0RDJC-3CRCummins/Onan 15.0RDJC-4RCummins/Onan 15.0RDJC-4XRCummins/Onan 15.0RDJC-5DRCummins/Onan 15.0RDJC-9XR

How to read your Cummins/Onan engine serial & model number →

Troubleshooting

7

Symptoms & remedies

SymptomCauseRemedy
Engine does not crank.Battery dead, loose connections, incorrect wiring, or faulty starter motor.Check 12 VDC to ground at battery BT1 and at starter motor Bl. Check B+ present at TB11, K13, S1, and M11. Check battery cables for polarity and tightness at battery and starter motor. If battery is dead, check if centrifugal switch S1 is open to ground. Replace S4 or charge battery. Jumper battery cable connection to ground at starter. Check starter motor. With S11 at START, jumper K11 contacts to starter solenoid. Start relay K11 is defective; replace it.
Engine cranks but does not start.Faulty switch or lead connections.Check 12 VDC present between start terminal on S11 and ground (TB11-1) with S11 at START. Check 12 VDC present between M11-B+ and ground TB11-1 with S11 at START. Replace faulty switch S11 if necessary. Check lead from TB12-4 to fuel pump; check fuel pump and replace if necessary.
Engine starts but stops when start switch is released.Faulty switch or lead connections.Connect voltmeter from 12 VDC to ground at battery BT1 and at starter motor Bl. Check B+ present at TB11, K13, S1, and M11. Check battery cables for polarity and tightness at battery and starter motor. If battery is dead, check if centrifugal switch S1 is open to ground. Replace S4 or charge battery. Jumper battery cable connection to ground at starter. Check starter motor. With S11 at START, jumper K11 contacts to starter solenoid. Start relay K11 is defective; replace it.
No build up of AC output voltage.Is Field Breaker CB21 on control panel ON? If not, step 2. Connect jumper wire across terminals of Field Breaker, CB21. Does AC output voltage build up? If yes, replace Field Breaker. If no, push to reset Field Breaker. Does AC output voltage build up? If yes but is high, low, unstable, or causes tripping of Field Breaker, refer to Tables B, C, or D. If no, step 4. Disconnect alternator stator leads 1 & 2 from TB21-1 and TB21-2 on VR22. Is reference voltage across 1 & 2 20 VAC or more? If not, refer to step 14.
AC output voltage builds up, but is unstable.Are there any loose or broken wires or connections on voltage regulator assembly VR22? If yes, step 3. Is W9 (exciter field) wiring harness from VR22 to End bell OK? If no, replace PC Board VR21. Do not replace the printed circuit board until the trouble not on the PC board has been located and corrected to avoid damage to new PC board.
AC output voltage builds up, but is high or low.Is set running at correct RPM? (See appropriate engine manual to set RPM) If no, step 3. Does adjustment of Voltage Adjusting knob for R22 on VR22 result in correct output voltage? If no, step 4. Does adjustment of potentiometer R26 on VR21 result in correct output voltage? If no, refer to step 5. Is correct voltage reference V4 to V1, V2, or V3 on VR21 being used? Refer to Figure 6. If no, replace voltage regulator PC board VR21. Do not replace the printed circuit board until the trouble not on the PC board has been located and corrected to avoid damage to new PC board.
AC output voltage builds up, but Field Breaker trips.Does AC output voltage build up to 140% or more of rated voltage before Field Breaker trips? If yes, are there any loose or broken wires or connections on VR22? If no, is diode CR15 on VR21 OK? If no, are T21 windings and connections OK? If no, are generator stator leads properly connected? Refer to Figure 6. Replace VR21 if necessary. Are diodes CR1, CR2, CR3, CR4, CR5, CR6 in rotating rectifier assemblies OK? Check all diodes - more than one may be defective. Is brushless exciter stator winding OK? Is generator rotor field winding OK? If no, is brushless exciter rotor windings OK?

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

Maintenance schedule

ItemSpecCapacityPart #Interval
Air filterDry type140-063650 hr Amazon eBay
Fuel filter122-0325600 hr Amazon eBay $75.00
Oil filterFull Flow Type122-0185200 hr Amazon $8.99 Amazon eBay $19.55 eBay
BatterySAE group 1H, 2 in series, amp/hr SAE 20-hr (nominal) 105
BeltDeflection 1/2-inch with about 15 pounds force midway between fan pulley and belt tightener pulley511-0066 Amazon eBay
CoolantClean, soft (alkali free) water with rust and scale inhibitor12.0 quarts
Coolant filter130-0626 Amazon eBay
OilAPI CD/SD or CD/SE6.0 U.S. quarts100 hr

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

Repair guides

3

Step-by-step procedures compiled from the Cummins/Onan service manual for this engine.

Service intervals

20
ItemActionHoursMonthsNotes
Fuel supplyCheck8 hrSee Note 1
Generator setInspect8 hr
Oil levelCheck8 hrSee Figure 17
Air cleanerCheck50 hrMore often in dusty conditions
Crankcase oilDrain50 hrFirst service — Drain and replace after first 50 hours of operation; drain while engine is still hot
Crankcase oilChange100 hr
Fuel condensation traps in lines and filtersDrain100 hr
Governor linkageClean100 hrSee Figure 17
Battery conditionCheck200 hr
Crankcase breatherClean200 hrSee Figure 17
Oil filterReplace200 hr
Generator slip rings and brushes (prior to Spec AA)Check500 hrReplace if worn to 5/16"
Start-disconnect circuitCheck500 hrCall Onan serviceman
Valve clearancesCheck500 hr
Primary filterChange600 hrFigure 18
Baffle in pulsation filterReplace2000 hrFigure 17
Holes in rocker box oil lineClean2000 hr
ValvesOther2000 hrGrind valves (if required)
Secondary fuel filterChange3000 hr
General overhaulOther5000 hrIf required - Call Onan serviceman (Note 3)

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

59
TypeItemValueUnitCondition
ClearanceCam Tappet Diameter.8725 (min) - .8730 (max)inch
ClearanceCam Tappet Hole Diameter.8755 (min) - .8765 (max)inch
ClearanceCamshaft Bearing Clearance Limit.0015 (min) - .0030 (max)inch
ClearanceCamshaft Bearing Journal Diameter, Front2.500 (min) - 2.505 (max)inchroom temperature 70 degrees F
ClearanceCamshaft Bearing Journal Diameter, Rear1.1875 (min) - 1.1880 (max)inchroom temperature 70 degrees F
ClearanceCamshaft End Play.007 (min) - .039 (max)inch
ClearanceConnecting Rod Bushing (piston pin clearance).0002 (min) - .0007 (max)inchThumb Push Fit
ClearanceConnecting Rod Clearance, Bearing-to-Crankshaft.001 (min) - .003 (max)inch
ClearanceConnecting Rod Large Bore Diameter2.1871 (min) - 2.1876 (max)inch
ClearanceConnecting Rod Small Bore Diameter1.044 (min) - 1.045 (max)inch
ClearanceCrankshaft Connecting Rod Journal Diameter2.0600 (min) - 2.0605 (max)inch
ClearanceCrankshaft End Play.010 (min) - .015 (max)inch
ClearanceCrankshaft Main Bearing Clearance.0030 (min) - .0043 (max)inch
ClearanceCrankshaft Main Bearing Journal Diameter2.2437 (min) - 2.4445 (max)inch
ClearanceCrankshaft Rod Bearing Clearance.0019 (min) - .0038 (max)inch
ClearanceCylinder Block Bore Diameter (valve guide).467 (min) - .468 (max)inch
ClearanceCylinder Diameter Limits3.4995 (min) - 3.5005 (max)inch
ClearanceDistance Center Large Bearing Bore to Small Bore5.998 (min) - 6.002 (max)inch
ClearanceExhaust Valve Guide Clearance.0025 (min) - .0045 (max)inch
ClearanceExhaust Valve Stem Diameter.3405 (min) - .3415 (max)inch
ClearanceIntake Valve Guide Clearance.0015 (min) - .0025 (max)inch
ClearanceIntake Valve Stem Diameter.3405 (min) - .3415 (max)inch
ClearancePiston Clearance to Cylinder Wall (measured 90 degrees to pin, just below oil ring groove).0055 (min) - .0075 (max)inch
ClearancePiston Ring Width, 2nd.0925 (min) - .0935 (max)inch
ClearancePiston Ring Width, 3rd.0925 (min) - .0935 (max)inch
ClearancePiston Ring Width, Top.0925 (min) - .0935 (max)inch
ClearanceValve Guide Inside Diameter, Exhaust (after reaming).344 (min) - .345 (max)inch
ClearanceValve Guide Inside Diameter, Intake (after reaming).342 (min) - .343 (max)inch
ClearanceValve Guide Outside Diameter.4690 (min) - .4695 (max)inch
ClearanceValve Seat Bore Diameter1.361 (min) - 1.362 (max)inch
ClearanceValve Seat Depth (from cylinder head face).433 (min) - .439 (max)inch
ClearanceValve Seat Insert Outside Diameter1.364 (min) - 1.365 (max)inch
GapCentrifugal start-disconnect switch point gap.020inch
GapPiston Ring Gap.010 (min) - .020 (max)inch
OtherAC frequency regulation5%
OtherCranking time limit (cranking limiter)45 to 90secondsdepending on ambient temperature
OtherEngine fails to start - cranking stopped by cranking limiter45 to 120seconds
OtherEngine speed equals frequency x 30 on 4 pole generator1800rpm60 hertz
OtherExhaust Valve Face45degrees
OtherGovernor preheat and crank timeabout 20secondsRUN position
OtherIntake Valve Face42degrees
OtherValve Guide Length1-25/32inch
OtherValve Seat Angle45degrees
OtherValve Seat Available Oversizes.002, .005, .010, .025inch
OtherValve Seat Width3/64 (min) - 1/16 (max)inch
PressureOil pressure gauge minimum after startat least 20psi
PressureValve Spring Load, Valve Closed45 (min) - 49 (max)lbs.
PressureValve Spring Load, Valve Open87.2 (min) - 97.2 (max)lbs.
SpeedCentrifugal switch closesabout 900rpmduring speed buildup
SpeedGoverned speed variation, no-load to full-loaddoes not vary more than 3 hertzhertzno load to full load
TorqueCylinder Head Bolt Torque44-46lbs.-ft
TorqueGenerator (end bell)35-38ft. lbs.
TorqueGlow Plug Torque10-15lbs.-ft
TorqueRotating rectifier diodes25 (or finger tight plus a quarter turn)in. lb.
TorqueRotor through stud130 to 150ft. lbs.
TorqueStator through stud55-60ft. lbs.
Valve clearanceValve Clearance, Exhaust.016inchcold
Valve clearanceValve Clearance, Intake.011inchcold
VoltageAC voltage regulationPlus or Minus 3%

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, soft (alkali free) water such as rain water; standard anti-freeze solution if exposed to freezingAdd an approved rust and scale inhibitor; anti-freeze proportioned to protect to at least 10 F below the lowest expected temperature12.0 quartsWater capacity (radiator cooled) 12 quarts; check radiator drain valve closed and cylinder block drain plug tight.
Engine oilAbove 30 F: SAE 30; 0 F to 30 F: SAE 10W or 5W-30; Below 0 F: SAE 5W-30API designation CD/SD or CD/SE. Use CC oil for the first fill only (50 hours)6.0 U.S. quartsMultigrade oils recommended at 30 F and below, not recommended above 30 F. Add oil of same brand between changes.
FuelNumber 2 diesel fuel (Number 1 diesel can be used below 32 F, during long periods of light load, or if preferred)Low sulfur content fuel having a pour point at least 10 F below the lowest expected temperatureKeep fuel clean and protected from adverse weather; leave room for expansion when filling the tank.
GreaseNon-conductive greaseLight coating on battery terminals retards corrosion.
OtherApproved rust inhibitorAdd to coolant in closed cooling systems.

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
Centrifugal switch adjustment adjustment

Tools: Feeler gauge

  1. Locate switch on the gear cover on the side of the engine above the oil filter.
  2. Loosen the stationary contact.
  3. Adjust the point gap to .020 inch.
  4. Replace burned or faulty points.
Charge rate adjustment adjustment

⚠ Adjust only when plant is stopped.

  1. Adjust only when plant is stopped.
  2. Move the adjustable resistor slide tap until the charging rate is approximately 2 amperes.
  3. For frequent starts, move slide tap nearer the ungrounded lead to increase charging rate slightly.
  4. Avoid overcharging.
Fan belt adjustment adjustment
  1. Loosen the nut on the belt tightener pulley shaft.
  2. Move the shaft left or right in the elongated slot in the pulley mounting bracket until a deflection of 1/2-inch is obtained.
  3. Deflection measured with about 15 pounds of force at a point midway between fan pulley and belt tightener pulley.
  4. Tighten nut securely.
Governor sensitivity adjustment adjustment

⚠ If the governor is too sensitive a rapid hunting condition occurs (alternate increasing and decreasing speed).

  1. Turn the sensitivity adjusting ratchet accessible through a covered access hole on the side of the blower housing.
  2. Radiator cooled: clockwise gives more sensitivity when full load is applied; counterclockwise gives less.
  3. City water cooled: counterclockwise gives more sensitivity; clockwise gives less.
  4. Adjust for maximum sensitivity without hunting, then readjust speed.
  5. Replace the knockout plug in the blower housing and secure the speed stud lock nut.
Governor speed adjustment adjustment

Tools: Tachometer

  1. Change spring tension by turning the governor spring nut.
  2. Turn the nut clockwise (more spring tension) to increase RPM.
  3. Turn counterclockwise to reduce governed speed.
  4. Hold a tachometer against the flywheel cap screw.
Battery connection installation

⚠ Battery polarity must agree with the rectifier located in the control box. If battery ground must be changed, reverse the rectifier connection.

  1. Connect battery positive (+) to starter engaging solenoid terminal post.
  2. Connect battery negative (-) to a good ground on the engine.
  3. Battery is connected for negative (-) ground.
  4. For 24 volt cranking, provide two 12 volt batteries connected in series (one battery negative to the other battery positive).
Bleed air from fuel system maintenance

⚠ Crank engine one revolution if the camshaft pump lobe is up, to permit hand priming.

  1. Disconnect the fuel return line.
  2. Operate the hand priming lever on diaphragm type fuel transfer pump until no air bubbles in fuel flow from the return line fitting.
  3. Connect the fuel return line.
  4. Return priming lever to lowest (disengaged) position to permit normal pump operation.
Filling heat exchanger maintenance

⚠ After running unit 10 minutes the closed cooling system is pressurized and hot. Open the 14 pound pressure cap slowly to vent pressure.

  1. Remove fill cap.
  2. Open fill vent valve (turn counterclockwise).
  3. Remove vent plug.
  4. Fill with coolant until vents begin to overflow.
  5. Close fill vent valve (turn clockwise).
  6. Replace vent plug and fill cap.
  7. Operate unit 10 minutes at full load and watch for leaks.
  8. Shut down unit; slowly open pressure cap, check level, fill system to top with coolant.
Oil filter change maintenance
  1. Place pan under old filter and remove by screwing counterclockwise.
  2. Clean filter mounting area.
  3. Install new filter, oil filter gasket and screw filter on clockwise until gasket touches mounting base.
  4. Tighten 1/2 turn.
Out-of-service protection (more than 30 days) maintenance

⚠ Discharged batteries are subject to severe damage if exposed to freezing temperatures. Store all batteries fully charged.

Tools: Trickle charger

  1. Run set until thoroughly warm; generator under at least 50 percent load.
  2. Shut down engine and drain oil base while still warm; refill and attach a warning tag indicating viscosity of oil used.
  3. Disconnect batteries and remove from vessel; maintain liquid level and use a trickle charger.
  4. Provide a suitable cover for the entire unit.
Break-in procedure operation

⚠ Continuous running under one half load during the first few hundred hours usually results in poor piston ring seating, causing higher than normal oil consumption and blowby.

  1. Run one half hour at 1/2 load.
  2. Run one half hour at 3/4 load.
  3. Run at full load.
  4. Drain and replace the crankcase oil after 50 hours of operation; drain while the engine is still hot.
Returning the set to operation operation

⚠ Do not smoke while servicing batteries. Explosive gases are emitted from batteries in operation.

Tools: Hydrometer

  1. Remove cover and all protective wrapping; remove plug from exhaust outlet.
  2. Check warning tag on oil base and verify oil viscosity is correct for ambient temperature.
  3. Clean and check battery; measure specific gravity (1.260 at 77 F [25 C]) and verify level at split ring.
  4. Check that fuel lines and fittings are secure, without leaks.
  5. Service cooling system with clean fresh water; prime water pump and bleed all air.
  6. Connect batteries and verify no loads are connected to generator.
  7. Start engine.
  8. Check all gauges; unit is ready for service.

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
110/190312-lead broad rangeT1 through T12
115/200312-lead broad rangeT1 through T12
12012-wire serviceT1 and T3 joined; T2 and T4 joined and grounded (white)Ungrounded load wire (black)
120/208312-lead broad range (Code 18R or 518R)T1 through T12Terminals V1, V2, V4
120/24013-wire serviceT1 and T4; T2 and T3; T0 center tapDelta connected (60 hertz 120/240 volt model has code -50)
120/2401Code 3C or 53C reconnectibleT1, T2, T3, T4Connect jumper W10 on the voltage regulator printed circuit board between terminal V4 (common) and V1, V2, or V3 as listed on the reconnection diagram.
127/220312-lead broad rangeT1 through T12
139/240312-lead broad rangeT1 through T12
220/380312-lead broad rangeT1 through T12
230/400312-lead broad rangeT1 through T12
24012-wire serviceT1 and T4 joined; T2 and T3 joined
240/416312-lead broad rangeT1 through T12
254/440312-lead broad rangeT1 through T12
277/480312-lead broad rangeT1 through T12
347/6003Code 9X prewired 4-wireT1, T2, T3, T0Special order 60 hertz generators prewired at factory

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

Parts cataloged across the Cummins/Onan RDJC family

63
Part #DescriptionCategory
140-0636Element and Retainer, Air Cleanerair_filter
300-1006Board Assembly, Regulatoravr
305-0534Regulator Assembly, Voltage (Complete)avr
511-0066Belt, Fanbelt
511-0067Water Pump Belt Heat Exchanger Pumpbelt
212-1064Brush, Collector Ringbrush
122-0325PRIMARY Fuel Filter Elementfuel_filter
122-0326SECONDARY Fuel Filter Elementfuel_filter
149-0408Filter, Secondary Fuel (Includes Cartridge)fuel_filter
149-0428Fuel Filter Elementfuel_filter
149-0846Cartridge (For 149-1078 Filter)fuel_filter
149-1078Filter, Fuel - Mounted Between Fuel Tank and Transfer Pumpfuel_filter
149-1046Repair Kit, Fuel Pumpfuel_pump
110-0546Gasket, Glow Pluggasket
110-1852Gasket, Headgasket
120-0580Gasket Kit, Oil Pumpgasket
122-0188Gasket, Filter Adaptergasket
132-0072Gasket, Water Pump Mountinggasket
140-0584Gasket, Air Cleanergasket
149-0455Gasket, Secondary Filter - Cartridge to Headgasket
149-0456Gasket, Secondary Filter Bowl to Covergasket
149-0493Gasket, Secondary Filter - Cartridge to Retainergasket
149-0517Gasket, Fuel Pump Bowlgasket
149-0792Gasket, Fuel Pump Mountinggasket
154-1057Gasket, Exhaust Manifoldgasket
168-0100Gasket Kit, Enginegasket
309-0145Gasket, Thermostat Cover / Thermostat Chambergasket
333-0106Glow Plug (12 Volt)glow_plug
503-0204Hose, Radiator Curvedhose
503-0400Hose, Radiatorhose
132-0114Impellerimpeller
147-0043Nozzle Only (Component of Nozzle & Holder Assembly)injector
147-0044Shield, Nozzle Heat (Steel)injector
147-0136Nozzle & Holder Assemblyinjector
122-0185Oil Filteroil_filter
110-1221Spring, Valveother_service
110-1278Valve, Exhaust (Stellite)other_service
110-1320Valve, Intakeother_service
110-1501Guide, Valveother_service
132-0111Repair Kitother_service
149-0463Valve, Checkother_service
304-0500Resistor, Tapped (Adjustable)other_service
309-01691 Begin Spec G 25 26other_service
333-0054Heater, Water Jacketother_service
522-0212Overhaul Kit, Setother_service
522-0264Overhaul Kit, Setother_service
120-0547Pump Assembly, Oilpump
132-0082Repair Kit, Water Pump (Includes Shaft and Bearing, Impeller, Fan, Hub and Gasket)pump
132-0105Pump, Water (Spec A through C)pump
132-0110Fresh Water Pump - With Metal Impellerpump
147-0231Pump, Injection (Includes Buttons 2, 4, 11, 12, Retaining Ring, Injection Lines and Governor Linkage Ball Joint)pump
147-0232Pump, Injection (Includes Buttons 2, 4, 11, 12, Retaining Ring and Governor Linkage Ball Joint)pump
149-1020Pump, Fuel Transferpump
132-0101Seal (captive water pump)seal
509-0086Seal, Oil - Rear Housing Plateseal
509-0088Seal, Governor Shaftseal
509-00904 Seal, Oil Intake Valve (Includes Retaining Rings) 12seal
130-0626Zinc pencil anode for heat exchangersensor
193-0104Sender, Water Temperature Gaugesensor
193-0108Sender, Oil Pressure Gaugesensor
309-0178'Switch, Thermostatic - Hi Engine Coolant Temperaturesensor
309-0179'Switch, Thermostatic - Hi Engine Coolant Temperaturesensor
309-0130Thermostatthermostat

Parts cataloged across all variants of this engine family — verify the exact part fits your specific variant and serial number before ordering.

Common questions

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

The Cummins/Onan RDJC engine has an oil capacity of 6.0 liters.

What is the displacement of the Cummins/Onan RDJC?

The Cummins/Onan RDJC has a displacement of 120.0 liters with 4 cylinders.

Which generators use the Cummins/Onan RDJC engine?

The Cummins/Onan RDJC powers 9 generator set(s), including Cummins/Onan 12.5RDJC-518R, Cummins/Onan 12.5RDJC-53CR, Cummins/Onan 12.5RDJC-57R, Cummins/Onan 15.0RDJC-18R, Cummins/Onan 15.0RDJC-3CR.

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

The Cummins/Onan RDJC oil change interval is every 100 hours.