Cummins/Onan — FIGURE 3-53, BRYCE/KIKI PUMP

For these Cummins/Onan models: 12, 0MDJC-3CR, 12.0MDJF-53CR, 15.0MDJF-3cR, 3omDJaiR, 4.0MCCK-3cR, 6.0MDJE-53CR, 6.5MCCK-3CR, 6.OMDJE-S18R, 612-4792, 7.SMOJE-18R, ISOMDJF-3GR.

Applies to: Cummins Onan 12 0Mdjf 53Cr, Cummins Onan 15 0Mdjf 3Cr, Cummins Onan 3Omdjair, Cummins Onan 4 0Mcck 3Cr, Cummins Onan 6 0Mdje 53Cr, Cummins Onan 6 5Mcck 3Cr, Cummins Onan 6 Omdje S18R, Cummins Onan 7 Smoje 18R, Cummins Onan Isomdjf 3Gr, Cummins Onan Mcck Spec H, Cummins Onan Mdje 8, Cummins Onan Spec H, Cummins Onan Tsmdje 3Cr

Procedure

1. 12. volt input. plunger up should be about t amp: iit much greater, the contacts did not open.
2. 6. jeter t information on adjusting the fuel solenoid plunger. GOVERNOR LINKAGE ADJUSTMENT With the engine shut off, proceed as follows: . Loosen locknuts on governor linkage and then er y Position governor arm and fuel control arm fully forward (toward front of engine and hold) Adjust governor linkage so that both ball joints fit and snap on without moving governor arm or fuel contro! lever from their forward positions. Tighten locknuts on governor linkage. Release fuel solenoid Plunger allowing fuel shut off with solenoid de-energiz oo TROUBLESHOOTING PUMP PROBLEMS Normally, little goes wrong with the injection pump after it is installed on the engine as long as timing is correct and clean fuel is used continually. The most common problem is caused by a delivery valve that may be held open by dirt or metal chipsthat pump installation. That is the reason protective covers must e used to keep foreign matter out of unassembled fuel system components. If the pump is suspected of causing mistires or poor operation: ‘* Check the temperature of each nozzle holder and exhaust port; the coolest cylinder is the faulty one. one cylinder at a time (like disconnecting a spark plug wire), to determine the faulty cylinder, the cylinder that looses the least power is misfiring, or not firing ‘The Bryce/Kiki fuel injection pumps are jon type units. All testing and galitraton should be done In accordance with Onan ‘and may void the pump warranty. Return alt ity pumps to the Onan factory for repairs, of ‘Otherwi centers. THROTTLING PINTLE NOZZLE TESTS The following tests will determine nozzle conditions using a manually operated test stand. Each nozzle must be removed from the engine for testing. Prior to testing, each nozzle must be cleaned, decarboned, and inspected as described for non-throttling pintle type nozzles earlier in this section. New or recon- ditioned nozzles must be thoroughly cleaned in Cleaning solvent or test oil to remove all traces of Preservative grease before testing. not be interchanged, Visual Check: Using Illuminated Magnifier
3. 1. Inspect nozzle valve for damaged or rough seat. 2 Inspect pintle for wear, damage, or out-of-round spray Cie rea body for damaged or carboned seat. 2 Slide Test
4. 1. Dip clean nozzle valve in filtered diesel fuel or test oil.
5. 2. Insert valve in nozzle body, Figure 3-55. » . Holding body almost vertical, pull valve out to one-third of its engaged length; then release valve. The released valve {because ofits weight) should slide down to its seat rs ‘capNuT ADJUSTING SCREW Nozze Testing Nozzles With Hand Operated Tester The proper tester can be used to check opening pray pattern Install cleaned and inspected nozzle in tester and proceed as follows
6. 1. Place nozzle in holder.
7. 2. Tighten nozzle nut finger tight, then using proper Connect delivery line between nozzle holder and test stand; be sure that fittings match properly. Test nozzle for jamming: > that nozzle opens 6-8 times per 6, Nozale should chatier vith «eh whiting Sound, if valve moves properly. 7 spray can cu through skin so any Aa lcrdeettoaimanemer esd ream could cause Blood poison KIKI NOZZLE ADJUSTMENT It ‘smooth jaw vise.
8. 1. Remove cap nut, Figure 3-56A. s Loosen locknut. Turn 2diusting screw to desired opening Totten | locknut to 45-50 ft. Ib. (61-68 Nem), Tighten cap nut to 45-50 ft. Ib. (61-68 Nem). Remove nozzle from tester and holder. e Coes jaw vise. Loosen locknut. Tum dlusting screw pres: Tohten cap nut to 45-50 ft. Ib. (61-68 Nem). Re-install plug using a thread sealant. Remove nozzle from tester and nozzle. en to desired opening oe PSI (150#5_ kg/cm?) (EAT 16 16208 Ka) fr es nozzles used on MDJE Spec AB oF iter Im about 200 PSI (14 kg/cm’) (1380 KPa) less after the nozzles have operated a few hundred hours. Open Leakage Test:
9. 1. Slowly depress hand lever until nozzle test gauge indicates 285 PSI (1966 kPa) below specified
10. 2. Consider nozzle leak-proof if no fuel (not even ‘one drop) emerges from nozzle tip within 10 seconds. Chatter Test
11. 1. Operate hand lever downward (1 or 2 nozzle opening cycles per second) until nozzle ejects a stream of fuel with a soft chattering sound.
12. 2. Take pressure readings trom gauge.
13. 3. Slightly increase hand lever movements (2 or 3 nozzle opening cycles per second), the stream velocity should increase and create a hissing
14. 4. Accelerate lever movements to 4-6 nozzle open- ing cycles per second. Thenozzleshould createa shrill whistling sound and a spray pattern aoe PATTERN opening and full lift causes the fuel to emerge in a stream, change to flag-like formations, and finally reach atomized spray pattern at full lift with lever movements producing 4-6 nozzle opening cycles per ADJUSTMENTS (DIESEL-POWERED UNITS) There are adjustments that must be checked periodically on a diesel engine to ensure long life, economy, and low service maintenance cost. The importance of making these adjustments according to the time intervals specified in the appropriate operators manual cannot be over emphasized. They are as follows © Throttle Stop Screw Governor Adjustments Valve Clearance Adjustments PSU Fuel Injection Pump Injector Nozzle Injector Pump Timing Timing Button Selection GOVERNOR The governor controls engine speed. Rated speed and voltage appear on the nameplate. The speed should not vary more than 3 cycles from no-load to full-load operation. Be sure throttle, linkage and governor mechanism operate smoothly. THROTTLE STOP SCREW 58 normally should not be adjusted in the field. This adjustment is set by the manufacturer. If original setting is disturbed, it can be adjusted as follows:
15. 1. Apply a momentary 10% overload to generator. (Example: If set rating is 15 kW, apply 16.5 kW load).
16. 2. Loosen lock nut and adjust stop screw until engine rpm starts to drop of
17. 3. Tighten lock nut on adjusting screw. Closes Stignty open Fully open {oilot ray) (main spray) MAXIMUM, THROTTLE STOP SCREW LockNur’ Speed Adjustment: To change the governor speed, change the spring tension by turning the governor spring tension) to increase governed speed and counterclockwise to reduce governed speed. Hold a tachometer against flywheel cap screw or use fre- quency meter. Sensitivis 7 ity (no-load to full-load speed drop), turn the sensitivity gives more sensitivity (less speed drop when full load is applied), clockwise gives less sensitivity (more speed drop). If the governor is too sensitive, a rapid hunting condition occurs (alternate increasing and decreasing speed). Adjust for maximum sensitivity without hunting. After sensitivity adjustment, the speed will require readjustment. After adjusting the governor, secure lock nut VALVE CLEARANCE ADJUSTMENTS Check valve clearance when the engine is at room temperature about 70° F (21° C)
18. 1. Turn the flywheel until the cylinder which is to retaining screw. stroke, observe the action of the push rods as the aligned with the timing pointer and the valve push rods stationary.
19. 2. Now turn the flywheel clockwise for an additional 10 to 45 degrees. There is no timing mark for this Position so it must be estimated. With the piston located in this position, it will be in its power stroke with both valves completely closed. vec INCREASE SENSITIVITY GOVERNOR P ARM Y GOVERNOR 34 SPRING SENSITIVITY RATCHET GOVERNOR STUD PEED = ° To change the setting of valve clearance, adjust the locknut which secures the rocker arm to the locknut to increase clearance and tighten it to reduce clearance. arm ent igure 36). Increase or reduce the clearance until the proper valve clearances. Always adjust the valve clearances in the firing order (1-2-4-3) sequence. After allowing engine to cool, adjust #1 cylinder. After timing the #1 cylinder, adjust the valve clearance according to Steps 2 and 3, To adjust the valve clearance of #2 cylinder, turn the flywheel in a clockwise direction from the position used when timing #1 cylinder (360° on 2 cylinder MDJB and MDJE units, 180° on 4 cylinder MDJC and MDJF units. After timing #2 cylinder, adjust the valve clearance according to steps 3 and 4 To adjust #4 cylinder valve clearance, turn the flywheel in a clockwise direction 180-degrees (one half revolution). The flywheel should be between 10- and 45-degrees past the TC (top center) flywheel mark. After timing cylinder, adjust clearance according to steps 3 and 4. the valve To adjust the valve clearance for #3 cylinder, turn iY ; iy ina (one half revoluti on), After timing #3 cylinder, adjust the valve clearance according to steps 3 and 4. VALVE CLEARANCES IN INCHES (mm) 020 (0.51) 018 (0.33) 011 (0.28) 016 (0.41) 017 (0.43) 017 (0.43) vatve SPRING RETAINER VALVE SPRING exHausT VALVES vaLve PUSH ROD SHORT steeve OWN ONLY 62 The following is the sequence of operation for starting of a diesel engine generator set: STARTING SEQUENCE - Diesel
20. 1. Operator holds Preheat switch for recommended time interval (see operating instructions). Heater solenoid closes and battery current flows to glow plugs and manifold heater. Operator pushes Start button, or setis started by remote control Start solenoid closes. Battery current flows to starting motor and gover- nor solenoid (full fuel). y e oe 2 . Engine cranks and starts Centrifugal switch closes. Start disconnect relay closes—keeps governor solenoid energized. . Operator releases Start button. Engine continues running. ex Be STOP SEQUENCE 1, Operator pushes Stop button.

Source: manual:932-0405 Onan Marine Genset MCCK MDJA MDJC MDJE MDJF Training Manual (07-1979).pdf. Figures and steps are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.