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Cummins/Onan 12.0MDJF-53CR Generator Set

The Cummins/Onan 12.0MDJF-53CR is a 4 kW diesel standby generator set powered by a Cummins/Onan MDJF (Onan J-series diesel) engine. It is available at 120 V and 32 V, 3-phase, 50 Hz and rated 4 A.

4 kW
Standby
1
Document types

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

Compare with other 0–5 kW Diesel generators →

Service parts for the 12.0MDJF-53CR

Grouped by system, with how many of each the parts manual calls for.

Air intake

1 required
140-0606Air filtersee priceAmazon

Fuel system

1 required

Oil system

1 required

Belts

1 required

Prices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.

Specifications

Fueldiesel
Frequency50.0 Hz
Standby power4 kW
Alternatorsolid state voltage regulated (4-pole)
Voltage options120 V, 32 V
Phase3
Rated current4.0 A
Power factor1
Circuit breaker141 A

Engine

Cummins/Onan MDJF (Onan J-series diesel)
Aspirationnaturally aspirated
Rated speed1800 rpm

Maintenance & consumables

for the Cummins/Onan MDJF (Onan J-series diesel)
ItemSpecCapacityPart #Interval
Air filter140-0606 Amazon eBay
Fuel filter122-0325600 hr Amazon eBay $75.00 NAPA $35.18
Oil filter122-0185100 hr Amazon Amazon eBay $19.55 eBay NAPA $12.88
BatterySAE group 1H, two in series, 12 volt source; 105 amp-hr (spec table lists 120 amp-hr SAE 20-hr nominal)—
Belt511-0067 Amazon eBay NAPA $4.76
CoolantClean alkali-free water plus approved rust inhibitor; anti-freeze if freezing—
Coolant filterRemove bolt, end cap and gasket at front end of heat exchanger; clean water passages—
OilAPI CD/SE or CD/SD; initial fill CC (formerly DM) oil for first 50-100 hours—100 hr

Service intervals

28
ItemActionHoursMonthsNotes
Cylinder head bolts and valve clearanceAdjust2 hrFirst service — Tighten head bolts and adjust valve clearance after first 2 hours on a new or overhauled engine
Exhaust systemInspect8 hrWith plant running, visually and audibly check for leaks
Fuel sediment bowlDrain8 hr
Fuel supplyCheck8 hr
Oil levelCheck8 hrShould be at full mark on oil indicator
UnitInspect8 hrOperator maintenance schedule
Water level (heat exchanger models)Check8 hr
Crankcase oilChange100 hrDirty conditions - change every 50 operating hours
Crankcase oilDrain50 hrFirst service — Drain initial oil after 50 hours while engine is still hot
Governor linkageClean100 hrPerform more often in extremely dirty conditions; lubricate old style linkage
Oil filterReplace100 hr
BatteryCheck200 hrKeep electrolyte level above plates
BrushesCheck200 hrReplace collector ring brushes when worn to 5/16 in; commutator brushes when worn to 5/8 in
CommutatorCheck200 hr
Fuel system condensation trapsDrain200 hr
Slip ringsCheck200 hrCritical maintenance schedule
GeneratorClean500 hr
Rocker box oil line holesClean500 hr
Valve clearanceCheck500 hr
Water pump (leaks and wear)Inspect500 hrReplace if necessary
Primary fuel filterChange600 hr
Secondary fuel filterChange600 hrReplace with every 5th change of the primary filter
Nozzle opening pressure and spray patternTest1000 hrMust be conducted by trained diesel injection equipment personnel
ValvesAdjust1000 hrGrind valves if required
Breather pulsation dampener elementReplace2000 hr
Fuel filtersChange2000 hr
EngineOther5000 hrGeneral overhaul if required
Zinc pencil (heat exchanger)Inspect2 moReplace if deteriorated to less than 1/2 original size

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
ClearanceCamshaft bearing clearance limit.0012-.0037in
ClearanceCamshaft end play (in back position).007-.039in
ClearanceClearance, large bearing to crankshaft.001-.0033in
ClearanceCollector ring run-out0.002incompared to generator bearing
ClearanceConnecting rod large bearing diameter (I.D.)2.0615-2.0630in
ClearanceConnecting rod small bushing diameter (I.D.)0.9903-0.9906in
ClearanceCrankshaft connecting rod journal diameter2.0597-2.0605in
ClearanceCrankshaft end play.010-.015in
ClearanceCrankshaft main bearing clearance (original equipment).0030-.0043in
ClearanceCrankshaft main bearing journal diameter2.2427-2.2435in
ClearanceCylinder diameter limits3.4995-3.5005in
ClearanceExhaust valve clearance in guide.0030-.0050in
ClearanceExhaust valve stem diameter.3405-.3415in
ClearanceIntake valve clearance in guide.0015-.0030in
ClearanceIntake valve stem diameter.3405-.3410in
ClearancePiston clearance to cylinder wall below oil ring groove.0055-.0075inmeasure 90 degrees to pin
ClearancePiston pin clearanceThumb Push Fit
ClearanceStarting motor armature end play.005-.030in
ClearanceStarting motor pinion clearance to pinion stop.070-.120insolenoid plunger bottomed
ClearanceStarting motor pinion rest position (pinion housing mounting face to outer edge of pinion)1-9/32 to 1-15/32in
ClearanceValve clearance.020 (0.51), .018 (0.33), .011 (0.28), .016 (0.41), .017 (0.43), .017 (0.43)inch (mm)engine at room temperature about 70°F (21°C)
GapBreaker point gap (MAJ)0.022inch (0.56 mm)full separation
GapBreaker point gap (MCCK)0.020inch (0.51 mm)
GapCentrifugal switch breaker points gap.040in
GapCentrifugal switch gap0.020 (0.51 mm)in
Injection timingIgnition timing (gasoline)19degrees BTC1800 rpm or slower
Injection timingIgnition timing (gasoline)25degrees BTC3600 rpm or faster
Injection timingInjection timing17degrees BTC
Injection timingInjection timing18degrees BTC
Injection timingInjection timing19degrees BTCLater models after Spec P
Injection timingInjection timing21degrees BTCBefore Spec P
Injection timingPLB pump timing (DJA)17degrees BTC
OtherBattery charging high rate6 to 8amps
OtherBattery charging low rate2 to 3amps
OtherBattery charging rate solid state combined5.26amps
OtherBattery charging rate solid state high3.7amps
OtherBattery charging rate solid state low1.56amps
OtherBilge blower time delay5minutes
OtherCooling water flow6gallons per minuteafter thermostat opens
OtherCranking limiter time45 to 90seconds
OtherCylinder bore3-1/2in
OtherEmergency relay K14 operation time15seconds
OtherEmergency time delay low oil shutdown45seconds
OtherExhaust valve face seat angle45degrees
OtherIntake valve face seat angle42degrees
OtherMaximum operation angle MCCK, MDJA, MDJE20degreesany direction
OtherMaximum operation angle MDJC, MDJF30degreesany direction
OtherStarting motor brush spring tension32-40ounceswith new brushes
OtherStarting motor no-load test10 volts - 80 amps, 5000 rpm Min.
OtherStarting motor stall torque4 volts - 420 amps, 7.8 lbs. ft. Min.
PressureDelivery valve line pressure300-600psi (2070-4140 kPa)engine running
PressureEngine oil pressure20psiminimum, pressure-relief valve is not adjustable
PressureFuel pump pressure (MDJA)5-6psi (34.5-41.4 kPa)at 1800 rpm
PressureFuel pump pressure (MDJC, MDJE, MDJF)12-14psi (83-97 kPa)at 1800 rpm
PressureFuel transfer pump vacuum15-18inches (25.4-43.4 mm)at sea level
PressureInjection line pressure1900psi (13,110 kPa)
PressureNozzle opening pressure1900-1950psi (13,110-13,455 kPa)
PressureNozzle opening pressure (Kiki/Yanmar)2133-2204psi (14707-15196 kPa)
PressureNozzle opening pressure after several hundred hours1750psi (12,075 kPa)

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, alkali-free waterAdd an approved rust inhibitor; anti-freeze if freezingClosed cooling (heat exchanger) system
CoolantantifreezeReplace annually in captive system
Engine oilAPI CD/SEDiesel engines; use CC/SE for first fill only (50 hours)
Engine oilAPI SE or SE/CCGasoline engines
Engine oilCC (formerly DM)Passing MS Sequence TestsFirst fill only (50 to 100 hours) for new or rebuilt J series diesel
Engine oilSAE 10W-30, 5W-20, or 10W, 5W-30API CD/SE or CD/SD0 deg F to 32 deg F
Engine oilSAE 30API CD/SE or CD/SD (Series 3 Test; MS Sequences IIA and IIIA)6.0 U.S. quartsAbove 32 deg F; do not mix brands or grades; plus 1/2 quart for new filter
Engine oilSAE 5W-20 or 5W-30API CD/SE or CD/SDThird temperature row (label not legible in source)
Engine oilSAE 15W-40 or 20W-40-10°C to 32°CJ-series water-cooled diesel engines
FuelASTM 2-D or 1-Dmin Cetane 45Diesel; use 1-D below 32°F (0°C)
FuelNo. 1 dieselLow sulfur content; pour point at least 10 deg F below lowest expected temperatureWhen ambient temperature is below 32 deg F, or at all temperatures during long periods of light engine load
FuelNo. 2 dieselBest economy
Fuelnonleaded gasolineRecommended for gasoline engines
Greasegraphite lubricantSteel governor ball joints

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 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 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.
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.
Checking Centrifugal Breaker Points adjustment

Tools: Thickness gauge, Socket wrench, File or fine stone

  1. Rotate engine crankshaft a few degrees counterclockwise before adjusting points (use socket wrench on flywheel retaining screw).
  2. Measure gap with a thickness gauge; set gap at .040 in.
  3. Loosen and move the stationary contact to correct gap.
  4. Dress slightly burned points smooth with a file or fine stone; replace burned or faulty points.
Checking and Adjusting Valve Clearance adjustment

Tools: Feeler gauge, Socket wrench

  1. Turn flywheel until cylinder to be adjusted is on compression stroke (socket wrench on flywheel screw hex head).
  2. Turn flywheel clockwise an additional 10 to 45 degrees so piston is on power stroke with both valves closed.
  3. Loosen the rocker arm locknut to increase clearance; tighten to reduce clearance.
  4. Using a feeler gauge, check clearance between rocker arm and valve; set to .017 in intake and .017 in exhaust.
  5. Always adjust valve clearances in the firing order (1-2-4-3) sequence, rotating flywheel 180 degrees between cylinders.
Governor Sensitivity Adjustment adjustment

⚠ If the governor is too sensitive, a rapid hunting condition occurs.

  1. Turn the sensitivity adjusting ratchet counterclockwise for more sensitivity (less speed drop at full load).
  2. Turn clockwise for less sensitivity (more speed drop).
  3. Adjust for maximum sensitivity without hunting.
  4. Readjust speed after sensitivity adjustment.
  5. Secure the lock nut.
Governor Speed Adjustment adjustment

⚠ Excessive droop may be caused by engine misfiring; correct this before adjusting the governor.

Tools: Tachometer or frequency meter

  1. Change spring tension by turning the governor spring nut.
  2. Turn nut clockwise (more spring tension) to increase RPM.
  3. Turn nut counterclockwise to reduce governed speed.
  4. Hold a tachometer against the flywheel cap screw or use a frequency meter.
  5. After adjusting, secure the lock nut.
Set Breaker Points (MAJ) adjustment
  1. Remove flywheel and examine breaker points.
  2. Adjust gap to .022 inch (0.56 mm) at full separation.
  3. Loosen screw to shift point set, retighten securely.
Time Ignition (MCCK) adjustment

Tools: continuity light, thickness gauge

  1. Crank engine to fully open breaker points.
  2. Loosen locking screws and turn cam to adjust.
  3. Set point gap to .020 inch (0.51 mm).
  4. Shift breaker point box to align timing mark.
Time PLB Pump (DJA) adjustment

Tools: depth micrometer

  1. Install pump tappet in recess, position flywheel on port closing mark.
  2. Measure distance from mounting pad to tappet center.
  3. Subtract from 1.670-inch port closing dimension.
  4. Select correct shims and install pump.

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
12012-wireReconnectible
120/24013-wireStandard connection for MCCK/MDJE/MDJC/MDJF
24012-wireReconnectible

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

How many kW is the Cummins/Onan 12.0MDJF-53CR?

The Cummins/Onan 12.0MDJF-53CR is rated 4 kW standby.

Which engine powers the Cummins/Onan 12.0MDJF-53CR?

The Cummins/Onan 12.0MDJF-53CR is powered by the Cummins/Onan MDJF (Onan J-series diesel) engine.

Is the Cummins/Onan 12.0MDJF-53CR diesel or gas?

The Cummins/Onan 12.0MDJF-53CR runs on diesel.

What voltage does the Cummins/Onan 12.0MDJF-53CR produce?

The Cummins/Onan 12.0MDJF-53CR is offered in 120 V, 32 V, 3-phase.

What alternator does the Cummins/Onan 12.0MDJF-53CR use?

The Cummins/Onan 12.0MDJF-53CR uses a solid state voltage regulated alternator. It has 4 poles.

Which oil filter part number does the Cummins/Onan 12.0MDJF-53CR take?

The Cummins/Onan 12.0MDJF-53CR uses oil filter part number 122-0185.

Which fuel filter part number does the Cummins/Onan 12.0MDJF-53CR take?

The Cummins/Onan 12.0MDJF-53CR uses fuel filter part number 122-0325.

What air filter does the Cummins/Onan 12.0MDJF-53CR use?

The Cummins/Onan 12.0MDJF-53CR uses air filter part number 140-0606.

Troubleshooting

6

Symptoms & remedies

SymptomCauseRemedy
Incomplete circuit between exciter and slip rings.Slip ring brush shunt brokenCheck all slip ring brush shunts with an ohmmeter and replace broken brush shunts.
Slip ring brushes not contacting the slip rings.Replace slip ring brush spring which may have come off or broken; or replace brushes which may have become worn down to far to contact the slip rings.
Insulating film on slip rings.Clean slip rings with stone or fine sandpaper and blow out dust.
Short circuit in fieldDampness or deteriorated insulation.Bake if damp, repair or replace if insulation is deteriorated.
Open circuit in fieldRough usage or original short circuit which may have burned a coil or connection.Examine field connections and test with ohmmeter. If a coil is open, replace it.
No generator output or low output.Defective shunt field bridge rectifierCheck AC components as listed above and preceding page. Check bridge rectifier with an ohmmeter. Replace if necessary.

Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing. Full Cummins/Onan 12.0MDJF-53CR troubleshooting guide (15 entries) →

Parts

52
Part #DescriptionQtySystem
122-0185Oil Filter1Oil filter Amazon Amazon eBay $19.55 eBay NAPA $12.88
122-0188Gasket, Oil Adapter1Gasket Amazon eBay
122-0325Filter, Fuel - Primary1Fuel filter Amazon eBay $75.00 NAPA $35.18
122-0326Filter, Fuel - Secondary1Fuel filter Amazon eBay $65.00 NAPA $37.59
131-0152Pump, Water (sets without heat exchanger)1Pump buy
131-0160Impeller (water pump 131-0152)1Impeller eBay KuduParts $234.00 FridayParts $244.13
131-0179Kit, Water Pump Repair1Pump eBay
132-0074Fresh water pump, with metal impeller1Pump Amazon eBay
132-0087Impeller (water pump 132-0074)1Impeller buy
132-0093Repair Kit, Water Pump (132-0074)1Pump Amazon eBay
132-0110Pump, Water1Pump Amazon eBay
132-0114Impeller1Impeller Amazon eBay
132-0115Pump, Water - Complete (units with heat exchanger)1Pump Amazon eBay
132-0116Repair Package, Water Pump (includes Parts Marked ‘)1Pump eBay
140-0606Element, Air Cleaner1Air filter Amazon eBay
147-0044Nozzle Only (component of Nozzle & Holder Assembly)4Injector Amazon eBay $24.95
147-0136Nozzle & Holder Assembly1Injector Amazon eBay
147-0232Pump, Fuel - Injection (includes mounting gasket)1Pump eBay
149-0408Filter, Secondary Fuel (Includes Cartridge)1Fuel filter Amazon eBay
149-0428Cartridge, Secondary Fuel Filter1Fuel filter Amazon eBay NAPA $20.57
149-1038Pump, Fuel Transfer1Pump buy
149-1046Repair Kit, Fuel Pump1Pump Amazon eBay
154-1057Gasket, Exhaust Manifold4Gasket Amazon eBay
168-0107Gasket Kit, Engine1Gasket buy
191-0434Brush Set, Service (starter, 12 Volt)1Brush Amazon eBay
191-0774Brush Set, Service (starter, 24 Volt)1Brush buy
214-0059Brush, Collector Ring2Brush buy
305-0264Rectifier Assembly, Resistor and Complete (exciter)1Avr buy
305-0388Rectifier Assembly, Resistor and Complete (exciter)1Avr buy
309-0130Thermostat1Thermostat Amazon eBay $55.00 NAPA $35.33
309-0156Cover, Thermostat Switch1Sensor Amazon eBay $150.00
309-0238Thermostat - mounts inside expansion chamber1Thermostat buy
333-0106Plug, Glow - 12 Volt (includes gasket)4Glow plug Amazon eBay
333-0107Glow Plug (24 Volt) - includes gasket1Glow plug Amazon eBay
333-0112Glow Plug (32 Volt) - includes gasket1Glow plug Amazon eBay $134.95
502-0076Gasket, Water Pump Mounting1Gasket buy
503-0217Hose, Rubber (3/4 in I.D. x 56 in) - heat exchanger hoses1Hose buy
511-0067Belt, Centrifugal Water Pump1Belt Amazon eBay NAPA $4.76
511-0068Water Pump Belt Keel Cooling Pump1Belt Amazon eBay
123-1061Damper, Breather Pulsation1Service part / kit Amazon eBay
130-0626Pencil, Zinc (Included in Heat Exchanger)1Service part / kit Amazon eBay
132-0111Repair Kit1Service part / kit Amazon eBay
149-0463Valve, Check1Service part / kit Amazon eBay
155-1004Muffler, Aqualift Marine1Service part / kit buy
304-0500Resistor, Tapped (Adjustable)1Service part / kit eBay $109.95
304-0534Resistor, Tapped Adjustable1Service part / kit buy
309-01691 Begin Spec G 25 261Service part / kit Amazon eBay
505-0057Plug, Square Head (1/8')1Service part / kit Amazon eBay
522-0242Overhaul Kit, Engine - units without heat exchanger1Service part / kit buy
522-0243Overhaul Kit, Engine - units with heat exchanger1Service part / kit buy
522-0252Overhaul Kit, Engine - units with heat exchanger1Service part / kit buy
522-0253Overhaul Kit, Engine - units without heat exchanger1Service part / kit buy

Service, wear & replacement parts referenced for this model and its engine — confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.

Available documents

Operator's manual — 968-0345 Onan MDJF Operators and Parts Spec A-D (6-1973) (Onan (Onan Division of Onan Corporation))Service manual — 932-0405 Onan Marine Genset MCCK MDJA MDJC MDJE MDJF Training Manual (07-1979) (Cummins/Onan)

This page was generated from the 2 manufacturer documents above by automated extraction; every figure shown is copied from one of them. How the data is compiled.

Full service, cheapest listings

Priced items from this model's own parts manual.

Fuel filter 122-0325$35.18
Oil filter 122-0185$12.88
Belt 511-0067$4.76
3 priced items$52.82