Onan MDKAD, MDKAE, MDKAF Owner's Manual

MDKAD, MDKAE, MDKAF

Printed in U.S.A.

03/03

981−0156

California

Proposition 65 Warning

Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

Table of Contents

SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INTRODUCTION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Identification 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Recommendations 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Recommendations 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher Port—Gensets with Sound Shields 8. . . . . . . . . . . . . . . . . . . . . . .

Typical Genset Configuration 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset-Mounted Control Panel 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Panels 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OPERATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Start Checks 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powering Appliances 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to Shore Power 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting Line Circuit Breakers 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Break-In 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No-Load Operation 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Exercise 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Genset Storage 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Returning the Genset to Service 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERIODIC MAINTENANCE SCHEDULE 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE PROCEDURES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Inspection 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Oil and Oil Filter 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cooling System 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel System 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Bearing 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Does Not Crank from Remote Panel 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Does Not Crank from Genset Panel 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Cranks but Does Not Start 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“Check Engine” Fault Shutdown 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

“Check Generator” Fault Shutdown 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Lacks Power or Is Unstable 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No Output Voltage 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HOW TO OBTAIN SERVICE 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE RECORD 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

Safety Precautions

Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can be obtained only by prop­er operation and maintenance.

The following symbols in this Manual alert you to
potential hazards to the operator, service personnel
and equipment.

alerts you to an immediate hazard
which will result in severe personal injury or
death.

WARNING

alerts you to a hazard or unsafe
practice which can result in severe personal in­jury or death.

CAUTION

alerts you to a hazard or unsafe
practice which can result in personal injury or
equipment damage.

Electricity, fuel, exhaust, moving parts and batteries
present hazards which can result in severe person­al injury or death.

GENERAL PRECAUTIONS

• Keep ABC fire extinguishers handy.

• Make sure all fasteners are secure and torqued

properly.

• Keep the genset and its compartment clean.
Excess oil and oily rags can catch fire. Dirt and
gear stowed in the compartment can restrict
cooling air.

• Let the engine cool down before removing the
coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
out and cause severe burns.

• Before working on the genset, disconnect the
negative (- ) battery cable at the battery to pre-
vent starting.

• Use caution when making adjustments while
the genset is running—hot, moving or electri­cally live parts can cause severe personal inju­ry or death.

• Used engine oil has been identified by some
state and federal agencies as causing cancer
or reproductive toxicity. Do not ingest, inhale,
or contact used oil or its vapors.

• Do not work on the genset when mentally or
physically fatigued or after consuming alcohol
or drugs.

• Carefully follow all applicable local, state and
federal codes.

• Do not step on the genset, as when entering or
leaving the engine room. The stress can break
genset parts leading to possible fuel or exhaust
leaks or electricution.

GENERATOR VOLTAGE IS DEADLY!

• Generator output connections must be made
by a qualified electrician in accordance with ap­plicable codes.

• The genset must not be connected to the public
utility or any other source of electrical power.
Connection could lead to electrocution of utility
workers, damage to equipment and fire. An ap­proved switching device must be used to pre­vent interconnections.

• Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth­ing and shoes are dry and stand on a dry wood­en platform on the ground or floor.

FUEL IS FLAMMABLE AND EXPLOSIVE

• Keep flames, cigarettes, sparks, pilot lights,
electrical arc-producing equipment and
switches and all other sources of ignition well
away from areas where fuel fumes are present
and areas sharing ventilation.

• Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.

• Use approved non-conductive flexible fuel
hose for fuel connections at the genset.

2

ENGINE EXHAUST IS DEADLY!

• Learn the symptoms of carbon monoxide poi­soning in this manual.

BATTERY GAS IS EXPLOSIVE

• Wear safety glasses and do not smoke while
servicing batteries.

• Never sleep in the vessel with the genset run­ning unless the vessel is equipped with a work­ing carbon monoxide detector.

• The exhaust system must be installed in accor­dance with the genset Installation Manual and
be free of leaks.

• Make sure the bilge is adequately ventilated
with a power exhauster.

MOVING PARTS CAN CAUSE SEVERE

PERSONAL INJURY OR DEATH

• Do not wear loose clothing or jewelry near mov­ing parts such as PTO shafts, fans, belts and
pulleys.

• Keep hands away from moving parts.

• Keep guards in place over fans, belts, pulleys,

etc.

• When disconnecting or reconnecting battery
cables, always disconnect the negative (- ) bat­tery cable first and reconnect it last to reduce
arcing.

DO NOT OPERATE IN FLAMMABLE AND

EXPLOSIVE ENVIRONMENTS

Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death.

where a flammable vapor environment can be
created by fuel spill, leak, etc., unless the gen­set is equipped with an automatic safety device
to block the air intake and stop the engine.

owners and operators of the genset are solely re­sponsible for operating the genset safely. Contact
your authorized Onan/Cummins dealer or distribu­tor for more information.

Do not operate a diesel-powered genset

The

POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE VESSEL

m-9

3

Specifications

MDKAD

DIMENSIONS AND WEIGHT

Without sound shield:

Length 40.5 inches (1028.7 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width 20.3 inches (515.62 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height 26.6 inches (675.64 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 780 pounds (353.8 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With sound shield:

Length 44.1 inches (1120.2 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width 23.3 inches (591.8 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height 28.8 inches (731 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 895 pounds (406 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR

Type: 4-pole revolving field, 4-wire reconnectible, 1800/1500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ratings: See Genset Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency regulation, no load-rated load: ± 1.5 Hz (5 percent) @ 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage regulation under varying load: ± 1 percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

Engine type: Kubota V1903B, diesel, 4 cylinder, vertical in-line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore: 3.15 in. (80 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke: 3.64 in. (92 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement: 113 in3 (1857 cm3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compression ratio: 23:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lube oil capacity: 8 qt. (7.6 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power (maximum) at 1800 rpm: 31 bhp (23 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power (maximum) at 1500 rpm: 26 bhp (19 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel consumption (No. 2 diesel fuel) average @ full load: 1.3 gph (4.9 L/h). . . . . . . . . . . . . . . . . . . . . . .

Fuel pump lift (self-priming) 48 in. (1.2 meters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel inlet 1/8-27, NPT, Female. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel return 1/8-27, NPT, Female. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total combustion air per minute required 1500 rpm: 42 ft3/min. (1.212 m3/min.). . . . . . . . . . . . . . . . . . . .

1800 rpm: 52 ft

Total cooling air per minute required (housed set) 1500 rpm: 100 ft3/min. (2.83 m3/min.). . . . . . . . . . . .

1800 rpm: 120 ft3/min. (3.4 m3/min.)

Total cooling air per minute required (unhoused set) 1500 rpm: 170 ft

1800 rpm: 200 ft3/min. (5.66 m3/min.)

Minimum compartment air opening (inlet) 40 in2 (258.1 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum compartment air opening (outlet) 40 in2 (258.1 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery charge alternator maximum output (regulated) 40 amperes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery voltage (nominal) 12 volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery recommendation minimum cranking performance @ 0

Coolant capacity 8 qt. (7.6 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant flow rate (60 Hz) 14 gpm (53 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant flow rate (50 Hz) 10 gpm (38 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water flow (60 Hz) 7 gpm (26.5 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water flow (50 Hz) 6 gpm (22.7 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water lift capability 36 inches (0.9 M) from water line to pump inlet. . . . . . . . . . . . . . . . . . . . . . . . . . .

° F (-18° C) 360 amp/hr. . . . . . . . . . . . .

3

/min. (1.454 m3/min.)

3

/min. (4.72 m3/min.). . . . . . . . . .

Kubota is a registered trademark of the Kubota Engine Company.

4

MDKAE

DIMENSIONS AND WEIGHT

Without sound shield:

Length 41.9 inches (1064.3 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width 20.3 inches (515.62 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height 26.6 inches (675.64 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 805 pounds (365.2 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With sound shield:

Length 45.5 inches (1155.7 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width 23.3 inches (591.8 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height 28.8 inches (731 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 920 pounds (417.3 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR

Type: 4-pole revolving field, 4-wire reconnectible, 1800/1500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ratings: See Genset Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency regulation, no load-rated load: ± 1.5 Hz (5 percent) @ 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage regulation under varying load: ± 1 percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

Engine type: Kubota V2203B, diesel, 4 cylinder, vertical in-line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore: 3.43 in. (87 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke: 3.64 in. (92.4 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

Displacement: 134 in

Compression ratio: 23:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lube oil capacity: 8 qt. (7.6 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power (maximum) at 1800 rpm: 36 bhp (27 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power (maximum) at 1500 rpm: 31 bhp (23 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel consumption (No. 2 diesel fuel) gph (L/h) average @ full load: 1.8 (6.8). . . . . . . . . . . . . . . . . . . . . . .

Fuel pump lift (self-priming) 48 in. (1.2 meters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel inlet 1/8-27, NPT, Female. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel return 1/8-27, NPT, Female. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total combustion air per minute required 1500 rpm: 50 ft3/min. (1.436 m3/min.). . . . . . . . . . . . . . . . . . . .

1800 rpm: 60 ft3/min. (1.723 m3/min.)

Total cooling air per minute required (housed set) 1500 rpm: 100 ft3/min. (2.83 m3/min.). . . . . . . . . . . .

1800 rpm: 120 ft

Total cooling air per minute required (unhoused set) 1500 rpm: 170 ft3/min. (4.72 m3/min.). . . . . . . . . .

1800 rpm: 200 ft3/min. (5.66 m3/min.)

Total air per minute required (cooling and combustion): 4.25 m3/min. (150 ft3/min.). . . . . . . . . . . . . . . . .

Minimum compartment air opening (inlet) 40 in2 (258.1 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum compartment air opening (outlet) 40 in2 (258.1 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery charge alternator maximum output (regulated) 40 amperes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery voltage (nominal) 12 volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery recommendation minimum cranking performance @ 0

Coolant capacity: 8 qt (7.6 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant flow rate (60 Hz) 14 gpm (53 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant flow rate (50 Hz) 10 gpm (38 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water flow (60 Hz) 7 gpm (26.5 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water flow (50 Hz) 6 gpm (22.7 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water lift capability 36 inches (0.9 M) from water line to pump inlet. . . . . . . . . . . . . . . . . . . . . . . . . . .

° F (-18° C) 360 ampere. . . . . . . . . . . .

3

/min. (3.4 m3/min.)

(2197 cm3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota is a registered trademark of the Kubota Engine Company.

5

MDKAF

DIMENSIONS AND WEIGHT

Without sound shield:

Length 48.5 inches (1232 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width 20.3 inches (516 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height 29.2 inches (742 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 970 pounds (440 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With sound shield:

Length 53.3 inches (1355 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Width 23.7 inches (602 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Height 31.6 inches (802 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight 1100 pounds (500 kg). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GENERATOR

Type: 4-pole revolving field, 4-wire reconnectible, 1800/1500 rpm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ratings: See Genset Nameplate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Frequency regulation, no load-rated load: ± 1.5 Hz (5 percent) @ 60 Hz. . . . . . . . . . . . . . . . . . . . . . . . . .

Voltage regulation under varying load: ± 1 percent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ENGINE

Engine type: Kubota V2803B, diesel, 5 cylinder, vertical in-line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bore: 3.43 in. (87 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stroke: 3.64 in. (92.4 mm). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement: 167.59 in3 (2746 cm3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compression ratio: 23:1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lube oil capacity: 13 qt. (12 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power (maximum) at 1800 rpm: 46 bhp (34.7 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power (maximum) at 1500 rpm: 38.3 bhp (28.6 kW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel consumption (No. 2 diesel fuel) gph (L/h) average @ full load: 2.5 (9.5). . . . . . . . . . . . . . . . . . . . . . .

Fuel pump lift (self-priming) 48 in. (1.2 meters). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel inlet 1/8-27, NPT, Female. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel return 1/8-27, NPT, Female. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total combustion air per minute required 1500 rpm: 63 ft

1800 rpm: 75 ft3/min. (2.12 m3/min.)

Total cooling air per minute required (housed set) 1500 rpm: 120 ft3/min. (3.4 m3/min.). . . . . . . . . . . . .

1800 rpm: 140 ft3/min. (4.0 m3/min.)

Total cooling air per minute required (unhoused set) 1500 rpm: 170 ft

1800 rpm: 200 ft3/min. (5.66 m3/min.)

Total air per minute required (cooling and combustion): 5.18 m3/min. (183 ft3/min.). . . . . . . . . . . . . . . . .

Minimum compartment air opening (inlet) 50 in2 (322 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Minimum compartment air opening (outlet) 50 in

Battery charge alternator maximum output (regulated) 40 amperes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery voltage (nominal) 12 volts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery recommendation minimum cranking performance @ 0° F (-18° C) 360 amperes. . . . . . . . . . .

Coolant capacity: 8 qt (7.6 L). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant flow rate (60 Hz) 14 gpm (53 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant flow rate (50 Hz) 10 gpm (38 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water flow (60 Hz) 9 gpm (34 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water flow (50 Hz) 7 gpm (27 L/min). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Raw water lift capability 36 inches (0.9 M) from water line to pump inlet. . . . . . . . . . . . . . . . . . . . . . . . . . .

3

/min. (1.78 m3/min.). . . . . . . . . . . . . . . . . . . . .

3

/min. (4.72 m3/min.). . . . . . . . . .

2

(322 cm2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Kubota is a registered trademark of the Kubota Engine Company.

6

Introduction

ABOUT THIS MANUAL

This manual covers operation and maintenance of
the model MDKAD, MDKAE and MDKAF generator
sets (gensets). Study this manual carefully and ob­serve all of its instructions and precautions. Using
the genset properly and maintaining it regularly will
promote longer genset life, better performance, and
safer operation. Each operator should become
thoroughly familiar with this manual. Keep this
manual in a convenient location for quick reference.

MODEL IDENTIFICATION

When you call for service or parts have the genset
model number and serial number ready (Figure 1).
For ready reference, record these numbers in the
boxes shown.

FUEL RECOMMENDATIONS

High quality fuel is necessary for good performance
and long engine life. Use No. 2 diesel fuel
(ASTM 2-D) with a Cetane number of not less than
45 and sulfur content of not more than 0.5 percent
(by weight). Where fuel is exposed to cold ambient
temperatures, use fuel that has a cloud point (tem­perature at which wax crystals begin to form) at
least 10 degrees below the lowest expected fuel
temperature.

WARNING

Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip­ment or in areas sharing ventilation with such
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a type ABC
fire extinguisher handy.

RECORD MODEL AND SERIAL NUMBERS HERE

MODEL NUMBER

SERIAL NUMBER

FIGURE 1. TYPICAL NAMEPLATE

7

ENGINE OIL RECOMMENDATIONS

Use premium quality motor oil. Look for the API
(American Petroleum Institute) classification and
use Class CG-4, CF-4, CF or better oil. Also look for
the SAE (Society of Automotive Engineers) viscos­ity grade. Referring to Figure 2, choose the viscos­ity grade appropriate for the range of ambient tem­peratures expected before the next scheduled oil
change. Multi-grade oils such as SAE 15W-40 are
recommended for year-round use.

BATTERIES

The genset requires either a 12 volt or 24 volt bat­tery to power its control and starting circuits. Reli­able genset starting and starter service life depend
upon adequate battery system capacity and main­tenance. See
ments and

Specifications

for battery require-

Periodic Maintenance

for battery care.

FIRE EXTINGUISHER PORT—GENSETS

WITH SOUND SHIELDS

FIGURE 2. SAE VISCOSITY GRADE vs. AMBIENT

TEMPERATURE

Gensets with sound shields have a fire extinguisher
port accessible by breaking through the circle on
the warning label located as shown in Figure 3.

Make sure that the nozzle of the fire extinguish­er that will be used in the event of fire is smaller
than the circle so that it will fit through the port

The fire extinguisher must be of the gaseous type

.

.

In the event of fire:

1. Do not open the genset sound shield.

2. Shut down engines, generators and blowers.

3. Break through the circle on the label with the
nozzle and discharge the full contents of the
fire extinguisher.

TYPICAL GENSET CONFIGURATION

Figure 4 illustrates a typical configuration of a gen­set, showing the components on the service and
non-service sides.

FIGURE 3. FIRE EXTINGUISHER PORT

8

CONTROL

PANEL

BATTERY

NEGATIVE (−)

DIPSTICK

FUEL

RETURN

OIL

POSITIVE (+)

SEA WATER

BATTERY

INLET

AIR INTAKE

RESONATOR

OIL DRAIN

VALVE

(MDKAF)

SOLENOID

FUEL PUMP

INLET

FUEL

FUEL

FILTER

OIL

FILL

EXCHANGER

FILTER

HEAT

OIL

COOLANT FILL AND

PRESSURE CAP

HEAT

EXCHANGER

REMOTE CONTROL

CONNECTOR

WET EXHAUST

OUTLET

FIGURE 4. TYPICAL GENSET CONFIGURATION

9

GENSET-MOUNTED CONTROL PANEL

Figure 5 illustrates a typical control panel with op­tional engine gauges.

Start-Stop-Prime/Preheat Switch (S1):

genset when held at Start and stops the genset
when momentarily touched to Stop. Holding the
switch at Stop causes the glow plugs to preheat the
combustions chambers and the fuel lift pump to
prime the fuel system.

Hour Meter (M1):

Indicates the number of hours

the genset has run. It cannot be reset.

Engine Gauges (M2, M3, M4):

Optional—indicate
engine oil pressure, coolant temperature and con­trol system DC voltage. If remote gauges have been
installed, push gauge switch (S6) in to read M2 and
M3 at the genset.

Gauge Switch (S6):

Momentary contact switch

used only when remote gauges have been

Starts the

installed. Push the button to read M2 and M3 at the
genset.

“Check Engine” Fault Breaker (CB2):

Shuts
down the genset when one of the following fault
conditions causes it to trip: overvoltage, overspeed,
low oil pressure, high exhaust temperature, high
coolant temperature and low coolant level (option­al).

Push the reset button to reset.

“Check Generator” Fault Breaker (CB5):

Shuts
down the genset when high generator quadrature
winding current causes it to trip.

Push the reset but-

ton to reset.

DC Circuit Breaker (CB1):

Protects the high-cur­rent (DC) glow plug circuits from shorts to ground.
The genset will stop if tripped.

Emergency Stop Breaker (CB4):

Reset with handle.

A rocker-switch
type of circuit breaker that protects the genset con­trol circuits (DC) from shorts to ground. The genset
will stop if the circuit breaker trips or the rocker is
pushed to Stop.

Push the rocker On to reset.

OIL PRESSURE

GAUGE M2

FAULT CIRCUIT

BREAKER CB2

COOLANT TEMPERATURE

GAUGE M3

GAUGE

SWITCH S6

DC CIRCUIT

BREAKER CB1

DC VOLTAGE

GAUGE M4

EMERGENCY STOP

HOUR

METER M1

BREAKER CB4

FAULT

BREAKER

CB5

START−STOP−PRIME/

PREHEAT SWITCH S1

FIGURE 5. GENSET-MOUNTED CONTROL PANEL

10

REMOTE CONTROL PANELS

Available remote control panels are shown in Fig­ure 6. The switch and gauges function the same
way as the ones on the genset-mounted control
panel. When a remote panel with gauges is

installed, oil pressure and coolant temperature nor­mally display at the remote panel rather than at the
genset. A momentary gauge switch on the genset
panel (Figure 5) can be provided to read the gauges
on the genset panel.

FIGURE 6. AVAILABLE REMOTE CONTROL PANELS

11

Operation

EXHAUST GAS IS DEADLY!

Engine exhaust contains carbon monoxide, a poisonous, odorless and colorless gas that can
cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:

•

Dizziness

•

Muscular Twitching

•

Weakness

GET EVERYONE OUT INTO FRESH AIR IMMEDIATELY IF ANYONE EXPERIENCES ANY OF
THESE SYMPTOMS. Seek medical attention if symptoms persist.

Never sleep in the vessel when the genset is running unless the cabin has an operating car­bon monoxide detector.

Look and listen for leaks along the entire run of the exhaust system every time you start up the
genset and every eight hours if the genset is being run continuously. Shut down the genset
immediately if there is a leak and do not run it until the leak has been repaired.

The installation of the exhaust system must be in accordance with the genset Installation
Manual.

•

Throbbing in Temples

•

Headache

•

Trouble Thinking Clearly

•

Nausea

•

Vomiting

•

Sleepiness

PRE-START CHECKS

Perform General Inspection (p. 17).

fuel, exhaust, oil and coolant leaks every eight
hours if the genset is being run continuously.

Check the
maintenance due (

ule

). Also see GENSET BREAK-IN if the genset is
new and RETURNING THE GENSET TO SER­VICE if the vessel has been in storage.

Maintenance Record

Periodic Maintenance Sched-

and perform any

Check for

STARTING

1. Disconnect all loads from the genset.

2. Preheat - Hold the control switch in the PRE-
HEAT position for 5 to 15 seconds.

CAUTION

seconds can damage the glow plugs.

3. Start - Immediately after PREHEAT push the
control switch to START and hold it there until
the engine starts. The starter will automatically
disconnect as the engine starts up.

Do not crank for more than 15 seconds at a
time. W ait two minutes before trying again. See

Preheat times longer than 15

Troubleshooting

the second try.

CAUTION

heat and damage the starter. Do not crank
for more than 15 seconds at a time and wait
two minutes before trying again.

4. Connect the electrical loads after the genset
has warmed up for a few minutes.

5. Check for fuel, exhaust, oil and coolant leaks
and complete General Inspection (p. 17).
Check the engine gauges regularly (if pro­vided) while the genset is running.

Oil Pressure Gauge:

•

pressure is 28 - 64 psi (194 - 442 kPa) at
normal operating temperature.

•

DC V oltmeter:

is 12.5 - 15 volts (12 volt system) or
24 - 27 volts (24 volt system) depending
on battery condition and state-of-charge.

Coolant Temperature Gauge:

•

engine coolant temperature is
160 -195
load and sea water* temperature.

if the engine does not start on

Excessive cranking can over-

Normal engine oil

Normal DC system voltage

Normal

°F (71 - 91° C) depending on

* In this manual, “sea water” refers to floatation water.

12

STOPPING

Before stopping

ning at no-load for three to five minutes. Then touch
the control switch momentarily to STOP.

CAUTION

before stopping can lead to engine damage. Let
the genset run three to five minutes at no-load
before stopping.

let the genset cool down by run-

Failure to let the engine cool down

POWERING APPLIANCES

The genset can power AC motors, air conditioners,
AC/DC converters and other appliances. How
much appliance load* can be serviced depends
upon the genset power rating. The genset will shut
down or its circuit breakers will trip if the sum of the
loads exceeds genset rating.

To avoid overloading the genset and causing shut­downs, compare the sum of the loads of the ap­pliances that are likely to be used at the same time
to the power rating of the genset. Use Table 1 or the
ratings on t h e appliances themselves (if so marked)
to obtain the individual appliance loads.

necessary to run fewer appliances at the same
time so that the sum of the loads is not greater
than genset rating.

It may be

TABLE 1. TYPICAL APPLIANCE LOADS

Appliance Load (watt)

Air Conditioner 1400-2000
Battery Charger Up to 800
DC Converter 300-1500
Refrigerator 600-1000
Microwave Oven 1000-1500
Electric Frying Pan/Wok 1000-1500
Electric Stove Element 350-1000
Electric Water Heater 1000-1500
Electric Iron 500-1200
Electric Hair Dryer 800-1500
Coffee Percolator 550-750
Television 200-600
Radio 50-200
Electric Drill 250-750
Electric Broom 200-500
Electric Blanket 50-200

Note that the genset may shut down due to over­load, even though the sum of the loads is less than
genset rating, when a large motor or air conditioner
is started last or cycles off and then on again. The
reason for this is that motor startup load is much
larger than running load.

It may be necessary to
run fewer appliances when large motors and air
conditioners are cycling on and off.

CONNECTIONS TO SHORE POWER

A vessel that has provisions for connection to shore
power must be equipped with an approved transfer
switch to keep the genset and shore power from be­ing interconnected.

WARNING

electrocution and damage to equipment. Use an
approved device to prevent the genset from be­ing interconnected with shore power.

Backfeed to shore power can cause

* Appliance load and genset power are measured in terms of watt (W) or kilowatt (kW), where 1 kilowatt (kW) = 1000 watt (W).

13

RESETTING LINE CIRCUIT BREAKERS

If a circuit breaker in the main power distribution
panel in the vessel or on the genset (Figure 7) trips,
there is either a short circuit or too much load. Note
that the genset will continue to run after a circuit
breaker trips.

If a circuit breaker trips, disconnect or turn off as
many appliances as possible and reset the circuit
breaker. (Push the circuit breaker OFF to reset it
and then ON to reconnect the circuit.) If the circuit
breaker trips right away, either the electrical dis­tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician.

If the circuit breaker does not trip, reconnect a com­bination of appliances that does not overload the
genset or cause the circuit breaker to trip. An ap­pliance that causes a circuit breaker to trip right
away probably has a short.

Electrical appliances must be properly grounded
and in good working condition.

CIRCUIT BREAKERS

(MAY BE ON OTHER END)

FIGURE 7. GENSET MOUNTED LINE CIRCUIT

BREAKERS

WARNING

Electrical shock can cause severe
personal injury or death. Read and follow the
appliance manufacturer’s instructions and
warnings.

ENGINE BREAK-IN

Change the oil and oil filter after the first 35 hours of
operation. See

Maintenance Procedures

.

NO-LOAD OPERATION

Keep no-load operation to a minimum. During

no-load operation combustion chamber tempera­tures drop to the point where fuel does not burn
completely, causing slobbering and white smoke.
Always have some load connected when the gen­set is run for long periods.

14

GENSET EXERCISE

If use is infrequent, run the genset at approximately
1/2 rated power for an hour every week. Exercising
the genset results in better starting, longer engine
life and increased genset reliability by driving off
moisture, re-lubricating the engine, using up fuel
before it becomes stale and removing oxides from
electrical contacts. One longer period during which
the engine and generator warm up thoroughly is
better than several shorter periods.

GENSET STORAGE

If the genset will be inactive for more than 30 days
and it is impractical to have someone exercise it,
prepare it for storage as follows:

1. Run the genset until it has thoroughly warmed
up and shut it down.

WARNING

out hot oil and cause severe burns. Stop the
engine before checking the oil level or
opening the fill cap.

2. Change the oil and oil filter while still warm and
attach a tag to the dip stick indicating the oil vis­cosity grade. See CHANGING OIL AND OIL
FILTER in

WARNING

a light switch or other equipment, flames
and sparks can ignite battery gas causing
severe personal injury. Ventilate the battery
compartment before connecting or discon­necting battery cables—Disconnect the
negative (-) cable first and reconnect it
last—Wear safety glasses—Do not
smoke—Switch lights ON and Off away
from the battery.

3. Disconnect the battery cables (negative [- ]
cables first) and store the battery(ies) in accor-

Crankcase pressure can blow

Maintenance Procedures

.

Arcing at battery terminals or in

dance with the manufacturer’s recommenda­tions.

WARNING

Hot coolant is under pressure
and can cause severe burns when loosen­ing the pressure cap. Let the engine cool
before loosening the pressure cap.

4. Check the coolant level and add coolant as
necessary. Test the coolant mixture if freezing
temperatures are possible and change if nec­essary. See ENGINE COOLING SYSTEM in

Maintenance Procedures.

5. If freezing temperatures are expected, drain
the heat exchanger of sea water by removing
the drain plug in the bottom of the heat ex­changer (Figure 9). Replace the plug when the
water has drained.

6. Clean the genset and lightly oil parts that can
rust.

RETURNING THE GENSET TO SERVICE

1. Check the tag on the dipstick and change the
oil if the viscosity is not suitable for present and
anticipated ambient temperatures.

2. Reconnect the battery(ies) (negative [- ] cables
last) and service as necessary in accordance
with the manufacturer’s instructions.

3. Prime the fuel system (p. 25).

4. Replace the sea water pump impeller if it was
installed more than a year ago. If less, remove
the impeller cover and wet the internal surfaces
of the pump with water to establish initial lu­brication and pump suction. See Replacing the
Sea Water Pump Impeller (p. 23).

5. Perform PRE-START CHECKS and start and
run the genset according to STARTING. Per­form maintenance or service as required be­fore placing the genset in service.

15

Periodic Maintenance Schedule

Periodic maintenance is essential for top genset
performance and long service life. Use Table 2 as a
guide, follow
maintenance performed in

PROCEDURE

Inspect Genset x
Check Oil Level x 17
Check Coolant Level x 17
Check Fuel Level x 17
Check Exhaust System x 17
Check Battery x
Check V-Belt Tension x
Drain Water in Fuel x 24

Maintenance Procedures

Maintenance Record.

TABLE 2. PERIODIC MAINTENANCE SCHEDULE

After

first

35 Hrs

and record

Every

Day/

8 Hrs

1

Every

Month/

100 Hrs

2
3

WARNING

Accidental starting can cause se­vere personal injury or death. Disconnect the
negative (-) cable(s) at the battery(ies) to pre­vent starting while working on the genset.

FREQUENCY

Every 6

Months/

200 Hrs

Every

Year/

500 Hrs

Every

800 Hrs

Every

2 years

Every

5 years

P
a
g
e

17

26
21

Check Siphon Break x 22
Clean Genset x 17
Change Oil & Oil Filter x x 18
Change Fuel Filter x 24
Change Zinc Anode x 22
Replace Sea Water Im-

peller
Adjust Valve Lash x
Change Coolant, Pres-

sure Cap, Thermostat,
Hoses, V-belt

Replace Generator
Bearing

1 - Check for oil, fuel, coolant and exhaust system leaks.
2 - See battery manufacturer’s recommendations.
3 - Check for slippage.
4 - Must be performed by an authorized Onan dealer.

x 23

4

x 19

x

-

4

-

16

Maintenance Procedures

GENERAL INSPECTION

Perform these checks and inspections every time
the genset is started or every eight hours if the gen­set is being run continuously.

Oil Level Check

WARNING

hot oil and cause severe burns. Stop the engine
before checking the oil level or opening the fill
cap.

Shut down the genset to check engine oil level and
wait a few minutes for the oil to drain down to the
crankcase to get an accurate indication of oil level.

Keep the oil level between FULL and ADD on the
dipstick (Figure 8). See ENGINE OIL REC­OMMENDA TIONS i n
to add.

CAUTION

gine damage and too much oil to high oil con­sumption and foaming, which can cause engine
shutdown. Keep the oil level between FULL and
ADD.

Crankcase pressure can blow out

Introduction

for the type of oil

Too little oil can lead to severe en-

Coolant Level Check

Exhaust System Inspection

Wet Exhaust System:

for leaks and loose hose clamps at the exhaust
manifold, exhaust elbow, muffler, water separator
and hull fittings. Replace damaged sections of ex­haust hose.

Dry Exhaust System:

for leaks at all joints, welds and gaskets. Replace
rusted sections of exhaust pipe.

WARNING

EXHAUST GAS IS DEADLY! Do not
operate the genset until all exhaust leaks have
been repaired.

Inspect the exhaust system

Inspect the exhaust system

Fuel System Inspection

Check for leaks at all fuel line fittings and gaskets.
Replace fuel hose that has been abraded or cut and
install new hose in such a way that it will not become
kinked, rub against other parts or come in contact
with sharp edges, hot surfaces or wiring.

WARNING

leaks immediately. Do not run the genset if it
causes fuel to leak.

Prime the fuel system if the genset ran out of fuel or
a fuel filter was replaced. See FUEL SYSTEM.

Fuel leaks can lead to fire. Repair

Replenish the normal loss of coolant by keeping the
level in the coolant recovery tank between COLD
and HOT. See COOLING SYSTEM for the recom­mended mixture of antifreeze and if it is necessary
to refill the system.

Sea Water Pump, Strainer and Sea Cocks

Clean out the sea water strainer if necessary and
make sure the sea cock is open. When a water sep­arator is part of the exhaust installation (Figure 12),
make sure the exhaust water sea cock is open.

If the sea water pump is located higher than the load
water line and it has been a week or more since the
genset was run, it is recommended that the impeller
cover be removed and the internal surfaces of the
the pump be wetted with water to establish initial lu­brication and pump suction. See Replacing the Sea
Water Pump Impeller (p. 23).

CAUTION

pump as often as necessary to prevent dry
startups, which severely shorten impeller life.

Wet the internal surfaces of the

Battery Inspection

Check for clean, tight battery connections. Loose
and corroded connections make for hard starting
because of high electrical resistance. See BAT­TERIES.

WARNING

Arcing at battery terminals or in a
light switch or other equipment, flames and
sparks can ignite battery gas causing severe
personal injury. Ventilate the battery compart­ment before connecting or disconnecting bat­tery cables—Disconnect the negative (-) cable
first and reconnect it last—Wear safety
glasses—Do not smoke—Switch lights ON and
Off away from the battery.

Mechanical Inspection

Check for unusual noises and vibrations, loose gen­set mounts and signs of mechanical damage.
Check the engine gauges regularly (if provided)
while the genset is running. See
mal gauge readings.

Operation

for nor-

17

Keep the genset clean. Do not clean the genset
while running. Protect the generator, control panel,
and electrical connections from cleaning solvents.

CHANGING OIL AND OIL FILTER

WARNING

termined that contact with used engine oil can
cause cancer or reproductive toxicity. Take care
to limit skin contact and breathing of vapors.
Use protective gloves and wash exposed skin.

See Table 2 for frequency of oil and oil filter change.
See ENGINE OIL RECOMMENDATIONS in

Introduction

the amount.

WARNING

hot oil and cause severe burns. Stop the engine
before checking the oil level or opening the fill
cap.

Draining Engine Oil:

the engine until thoroughly warm and then stop it. If
an oil pump-out system is installed, follow the in­structions provided. If not, unscrew the plug on the
end of the drain hose (Figure 8) and drain the oil into
a suitable container. When the oil is completely

State and federal agencies have de-

for the oil to use and

Specifications

for

Crankcase pressure can blow out

To drain the engine oil, run

drained, reinstall the plug and return the hose to its
storage position. Two wrenches are necessary to
keep from twisting the hose when removing and
tightening the plug.

Changing Oil Filter:

To change the oil filter, place a
container under the oil filter (Figure 8) to catch oil
that drips out and then spin off the oil filter. Clean the
filter mounting surface, apply oil to the new filter
gasket and spin the filter on until the gasket just
touches the mounting pad. Then tighten an addi­tional 3/4 turn.

Refilling Engine Oil:

Refill with the proper amount
of oil, start the engine and check for leakage around
the filter gasket.

stop leakage.

Tighten the filter only enough to

Shut off the genset, recheck the oil

level and add oil as necessary.

CAUTION

Too little oil can lead to severe en­gine damage and too much oil to high oil con­sumption and foaming, which can cause engine
shutdown. Keep the oil level between FULL and
ADD.

Disposing of Used Oil and Oil Filter:

Dispose of
the used oil and oil filter according to local environ­mental regulations.

OIL DIPSTICK

OIL DRAIN VALVE

(MDKAF)

OIL DRAIN HOSE

(MDKAD, MDKAE)

OIL FILL

OIL FILTER

FIGURE 8. OIL CHECK, FILL, DRAIN AND FILTER

18

ENGINE COOLING SYSTEM

Changing Coolant

See Table 2 for frequency of coolant, pressure cap,
thermostat, hose, V-belt and zinc anode replace­ment.

Cooling System Overview

The engine is cooled by a pressurized, closed-loop
liquid cooling system. Coolant is pumped through
passages in the engine block, head and exhaust
manifold and is cooled in a genset-mounted heat
exchanger or keel cooler. The top V-belt pulley
drives the coolant pump.

If the genset has a heat exchanger and/or a wet ex­haust elbow, the engine is equipped with a sea wa­ter* pump driven by a power takeoff on the engine.
The sea water cools the heat exchanger and/or ex­haust gases and exits the vessel through the ex­haust system. (There is no sea water pump if the
genset is equipped for keel cooling and dry ex­haust.) Figure 9 illustrates a typical installation of a
genset equipped with a heat exchanger, wet ex­haust elbow and sea water pump.

Recommended Coolant Mixture

Use the best quality ethylene or propylene glycol
antifreeze solution available. It should be fully for­mulated with rust inhibitors and coolant stabilizers

but not with stop-leak additives

. Use fresh water
that is low in minerals and corrosive chemicals. Dis­tilled water is best. Unless prohibited by shipping
regulations, gensets with heat exchangers are
shipped with the recommended 50/50 mixture of
water and ethylene glycol, which is good for -34

° C).

(-37

Specifications

See

for coolant system fill capacity if

° F

the genset is equipped with a heat exchanger. If the
genset is keel cooled, system capacity also de­pends on the capacity of the keel cooler.

Coolant Recovery Tank

Replenish the normal loss of coolant by keeping the
level in the recovery tank between COLD and HOT.
Use the recommended mixture of antifreeze. See
Changing Coolant if it is necessary to fill the system.

WARNING

Hot coolant is under pressure and
can cause severe burns when loosening the
pressure cap. Let the engine cool before loos­ening the pressure cap.

WARNING

Accidental starting can cause se­vere personal injury or death. Disconnect the
negative (-) cable(s) from the battery(ies) to pre­vent the engine from starting.

Draining the System:

Let the engine cool down,
disconnect the negative (- ) cable(s) at the bat­tery(ies) to prevent the engine from starting, re­move the system pressure cap and open the block
and heat exchanger drain cocks (Figure 9). See the
manufacturer’s instructions regarding a keel cooler .
Collect used coolant in containers for proper dis­posal.

WARNING

Ethylene glycol antifreeze is con­sidered toxic. Dispose of it according to local
regulations for hazardous substances.

Cleaning and Flushing the System:

Use radiator
cleaning chemicals to clean and flush the cooling
system before new coolant is added. Follow the
manufacturer’s instructions.

CAUTION

Filling a hot engine with cold water
can cause cracks in the manifold, head and
block. Follow the manufacturer’s instructions
for cleaning and flushing.

Filling the System:

Close all drain cocks and se­cure all hose clamps and fill the system through the
fill opening. The system will fill only as fast as the air
can escape. Fill to the bottom of the fill neck. Start
and run the engine for a minute to dislodge air pock­ets and shut it down. Add as much coolant as nec­essary and secure the pressure cap.

CAUTION

Low coolant level can cause severe

engine damage. Make sure the system is full.

Pressure Cap

Replace the pressure cap as recommended
(Table 2) to maintain optimal engine cooling and
minimal coolant loss.

* In this manual, “sea water” refers to floatation water.

19

COOLANT RECOVERY TANK

(REFILL NORMAL COOLANT LOSS HERE)

DRAIN TUBE

(ROUTE TO DRIP PAN)

COOLANT PRESSURE CAP

(REFILL SYSTEM HERE)

COOLANT

COOLANT

DRAIN

HEAT EXCHANGERMDKAD, MDKAE

COOLANT

COOLANT

SEA

WATER

SEA

WATER

COOLANT

DRAIN

SEA WATER

DRAIN

COOLANT

HOSES

ZINC ANODE

CLEANOUT COVERS

(BOTH ENDS)

COOLANT

COOLANT

DRAIN

HEAT EXCHANGERMDKAF

COOLANT

CLEANOUT COVERS

SEA

WATER

SEA

WATER

COOLANT

ZINC ANODE &

SEA WATER DRAIN

WET

EXHAUST

(BOTH ENDS)

COOLANT

DRAIN
VALVE

SEA WATER

HOSES

HEAT

EXCHANGER

FIGURE 9. TYPICAL HEAT EXCHANGER-TYPE COOLING SYSTEM

SEA WATER

STRAINER

20

SEA WATER

PUMP

SEA COCK

SEA WATER HULL

STRAINER

(SLOTS PARALLEL

TO KEEL)

Adjusting V-Belt Tension

The V-belt (Figure 10) drives the coolant pump and
battery charging alternator.

WARNING

Accidental starting can cause se­vere personal injury or death. Disconnect the
negative (-) cable(s) at the battery(ies) to pre­vent the engine from starting.

1. Disconnect the negative (- ) cable(s) at the bat­tery(ies) to prevent the engine from starting
and remove the belt guard or sound shield
door.

2. Loosen the alternator pivot bolt first and then
the adjusting bracket bolt on top.

3. Tighten belt tension by pivoting the alternator
outwards. Hold tension by tightening the ad­justing bracket bolt. Apply 20 pounds (10 kg) as
shown to the middle of the pulley span and
measure belt deflection, which should be 0.4
inch (10 mm). Tighten the alternator bolts
when tension is correct.

4. Secure the b e l t guard or sound shield door and
reconnect the battery cables (negative [- ]
last).

ADJUSTING BRACK-

ET BOLT

PIVOT

BOLT

0.4 INCH (10 MM)
DEFLECTION AT

20 LBS (10 KG)

FIGURE 10. ADJUSTING V-BELT TENSION

Replacing Thermostat

Replace the thermostat (Figure 9) at the recom­mended frequency (Table 2) to maintain optimal en­gine cooling.

WARNING

vere personal injury or death. Disconnect the
negative (-) cable(s) at the battery(ies) to pre­vent the engine from starting.

WARNING

can cause severe burns when loosening the
pressure cap. Let the engine cool before loos­ening the pressure cap.

1. Let the engine cool, loosen the pressure cap
and disconnect the negative (- ) cable(s) at the
battery(ies) to prevent the engine from starting.

2. Remove the two thermostat housing bolts (Fig­ure 11) and pull off the housing, thermostat and
gasket. The hose does not need to come off.

3. Clean off the gasket area and reassemble as
shown with the new thermostat and gasket. Ap­ply Three Bond 1215 liquid sealant or equiva­lent to the top side of the gasket.

Accidental starting can cause se-

Hot coolant is under pressure and

THERMOSTAT

FIGURE 11. REPLACING THERMOSTAT

21

Heat Exchanger and Zinc Anode

The heat exchanger has cleanout covers on both
ends to clean the sea water tubes. Remove the cov­ers to clean out seaweed and pump debris. If nec­essary, take the heat exchanger to a radiator shop
for chemical cleaning of hard deposits. Replace the
zinc anode as recommended (Table 2).

Siphon Break

A siphon break is installed when the exhaust elbow
is below, or less than 6 inches (152 mm) above, the
load water line (Figure 12) to prevent flooding when
the engine is not running. If of the spring-loaded

valve design, check for free movement of the plung­er. Replace the device if the plunger does not move
freely or the body is encrusted with deposits from
leakage past the valve seat. If of the bleed-vent
type, check that the vent hose is properly connected
on both ends. If the vent is connected to a hull fitting,
check for normal water flow whenever the engine is
running.

WARNING

Bypassing a siphon break or failing
to maintain it can lead to engine flooding and
damage to the engine not covered under War­ranty.

12 INCH (305 MM) MINIMUM HEIGHT OF

SIPHON BREAK ABOVE LOAD WATERLINE

VENTED
SIPHON

BREAK

A SIPHON BREAK IS REQUIRED WHEN

THE EXHAUST ELBOW OUTLET IS BELOW

OR LESS THAN 6 INCHES (152 MM)

ABOVE THE LOAD WATER LINE

SIPHON BREAK VENT LINE CONNECTED TO THIS RE-

GION OF EXHAUST TUBE OR TO HULL FITTING.

LOAD WA-

TERLINE

MUFFLER

FIGURE 12. TYPICAL INSTALLATION OF A VENT-TYPE SIPHON BREAK AND WET EXHAUST SYSTEM

22

Replacing the Sea Water Pump Impeller

The sea water pump (Figure 13) is driven off a pow­er takeoff on the engine. To replace the flexible im­peller:

1. Disconnect the negative (- ) cable(s) at the bat­tery(ies) to prevent the engine from starting.

SEA WA-

TER IN

WARNING

Accidental starting can cause
severe personal injury or death. Discon­nect the negative (-) cable(s) at the bat­tery(ies) to prevent the engine from start­ing.

2. Close the sea cock and remove the impeller
cover and O-ring.

3. Using two pairs of pliers to grip vanes on oppo­site sides, pull out the old impeller .

It will be nec­essary to check for and cleanout pieces of the
impeller from the heat exchanger and exhaust
elbow if vanes have broken off.

4. Install the new impeller. I t helps to twist the im­peller clockwise while squeezing it into the
housing. Push it in all the way when the keyway
lines up with the key in the shaft. The vanes
should all incline backwards, that is, counter­clockwise; the impeller turns clockwise.

5. To provide initial lubrication and better pump
suction before water reaches the pump, wet
the inside of the pump and impeller with water,
soap solution or a silicone lubricant and secure
the O-ring and cover.

COVER

O-RING

FLEXIBLE

IMPELLER

IMPELLER ROTATION, VANE

INCLINATION AND FLOW

SEA WATER TO

HEAT EXCHANGER

OR EXHAUST EL-

BOW

CAUTION

Do not lubricate with petroleum
products like grease and oil which chemi­cally attack impeller materials.

6. If the sea water strainer is above the water line,
remove the strainer element cover, fill it with
water (which also fills the hose to the pump)
and reinstall the cover.

7. Open the sea cock, reconnect the battery
cables (negative [- ] last) and start the genset.

Shut down the genset within 30 seconds if
there is no water flow from the exhaust hull fit­ting. (Flow will not be visible if an exhaust water
separator has been installed. In that case, feel
the pump cover and shut down the genset if the
pump gets hot.)

If there is no flow, find and re­move the blockage before the genset is started
again.

WARNING

The pump gets hot quickly if
there if no flow and can burn your fingers.
Be cautious when touching the pump.

FIGURE 13. REPLACING SEA WATER PUMP IM-

PELLER

23

FUEL SYSTEM

Fuel Handling Precautions

Keep dirt, water and other contaminants from enter­ing the fuel system and damaging, corroding or
clogging fuel injection components. The genset has
a water-separator type of fuel filter but the fuel sup­ply system should have a filter and water separator
installed ahead of connections at the genset.

A primary source of water in fuel, which can clog fuel
passages by freezing and cause corrosion by form­ing sulfuric acid with the sulfur in the fuel, is the con­densation of humid air on the walls of the fuel tank.
Keeping fuel tanks as full as possible reduces con­densation by reducing the area on which condensa­tion can take place.

Fuel Filter

Draining Water and Sediment:

regular frequency of draining water and sediment.

See Table 2 for the

Drain more often if fuel quality is poor or condensa­tion cannot be avoided. To drain the filter, remove
the plug (Figure 14), collect the water and sediment
(about 1/2 cup [120 ml]) in a suitable container and
dispose of properly.

Replacing the Filter Element:

Reinstall the plug securely.

See Table 2 for the
regular frequency of fuel filter change. Replace the
filter sooner if the engine lacks power or surges.

1. Drain the filter as explained above and spin off
the element.

2. Clean the contact surface of the base.

3. Lubricate the new element and its gasket, and
fill the element with clean diesel fuel.

4. Spin the new element onto the base and hand
tighten.

5. Start and run the genset and check for fuel
leakage. Tighten the filter only enough to stop
leakage. See Priming the Fuel System if the
genset does not start.

FUEL

SOLENOID

FUEL RETURN
CONNECTION

FUEL INJECTION

FUEL SUPPLY

CONNECTION

PUMP

FUEL

PUMP

FUEL

FILTER

FIGURE 14. FUEL SYSTEM

24

Priming the Fuel System

Priming the Low-Pressure Side:

pump (Figure 14) runs during preheat when the
control switch is held in the stop position, priming
the low-pressure side of the fuel injection system.
Because the glow plugs are on during priming, do
not prime for more than 15 seconds at a time.

CAUTION

Preheating for more than 15 sec­onds at a time reduces the life of the glow plugs.
Let the glow plugs cool for at least one minute
before trying again.

If more priming is necessary, disconnect the en-

gine harness from the end glow plug terminal and
insulate the harness lead so that it cannot ground
on the block (Figure 15). On Model MDKAD or
MDKAE, open the bleed valve (counterclockwise)
to bleed air and fuel back to the supply tank while
priming. (This is not necessary on Model MDKAF,
which has a fixed-orifice bleed.) Then prime, hold­ing the control switch in the stop position as long as
necessary to remove all air from the fuel supply sys­tem.

The fuel lift

Note: On Model MDKAD or MDKAE, if air entrainment
in the fuel supply line continues to be a problem, it
may be advisable to leave the bleed valve open to
bleed air continuously while running.

Priming the High-Pressure Side:

This procedure

should only be performed by a diesel mechanic.

WARNING

The high pressure oil spray from an
injector line fitting can penetrate the skin, lead­ing to possible blood poisoning. Wear safety
glasses and keep your hands away from the
spray. Do not delay getting proper medical
attention if oil spray penetrates your skin.

1. Loosen the high pressure fittings at the
nozzles. Use two wrenches to keep from twist­ing the return fittings. Use flare-nut wrenches
to keep from rounding the shoulders.

2. Crank the genset until fuel appears at the loos­ened fittings and then snug up each fitting. The
engine should start and run when the first fitting
is snugged.

3. Shut down the engine and torque the fittings to
19 - 25 lb-ft (25 - 34 N-m).

TO PRIME MORE THAN 15 SECONDS,

DISCONNECT ENGINE HARNESS FROM THIS

GLOW PLUG TERMINAL AND INSULATE LEAD END

BLEED VALVE

(MDKAD, MDKAE ONLY)

AVOID LOOSENING

THESE FITTINGS

USE TWO FLARE−NUT WRENCHES TO LOOSEN THESE

FITTINGS TO BLEED HIGH PRESSURE INJECTOR LINES

WEAR SAFETY GLASSES AND KEEP FINGERS OUT OF SPRAY

FIGURE 15. PRIMING THE FUEL SYSTEM

25

BATTERIES

GENERATOR BEARING

Sealed, maintenance-free batteries are recom­mended. Follow the manufacturer’s instructions for
battery care. Keep the terminals clean and tight.

WARNING

Arcing at battery terminals or in a
light switch or other equipment, flames and
sparks can ignite battery gas causing severe
personal injury. Ventilate the battery compart­ment before connecting or disconnecting bat­tery cables—Disconnect the negative (-) cable
first and reconnect it last—Wear safety
glasses—Do not smoke—Switch lights ON and
Off away from the battery.

WARNING

Accidental starting can cause se­vere personal injury or death. Disconnect the
negative (-) cable(s) at the battery(ies) to pre­vent the engine from starting.

Inspect the generator bearing every 1000 hours for
evidence of outer race rotation. Because bearing
grease deteriorates (oxidizes), have the generator
bearing replaced every five years.

26

Troubleshooting

GENERAL

Fault Circuits

“Check Generator” Fault:

tor” fault breaker on the control panel trips, as indi­cated by an extended reset button, the genset may
have been overloaded.

set.

“Check Engine” Fault:

nected to switches and sensors on the engine that
cause it to shut down the genset in the event of low
engine oil pressure, high coolant temperature, high
exhaust temperature or low coolant level (optional).
The automatic voltage regulator (AVR), which is
also inside the control box, causes the control to
shut down the genset in the event of over-speed or
over-voltage. If any of these fault shutdowns occurs
the “Check Engine” fault breaker on the control pan-

If the “Check Genera-

Push the reset button to re-

The genset control is con-

ENGINE DOES NOT CRANK FROM REMOTE PANEL

el will trip, as indicated by an extended reset button.

Push the reset button to reset.

Engine Gauges

Troubleshooting time can be saved if abnormal en­gine gauge readings were noted before shutdown;
that is, whether shutdown was due to low oil pres­sure or to high engine temperature. Note that shut­down occurs when oil pressure falls below 14 psi
(97 kPa) or engine temperature reaches 222
(106

° C).

° F

Troubleshooting Tables

The following troubleshooting tables are designed
to help you think through genset problems. The
problem could be as simple as an empty fuel tank,
closed fuel shutoff valve or tripped circuit breaker. If
you fail to resolve the problem after taking the cor­rective actions suggested, see

.

vice

How to Obtain Ser-

WARNING

vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

There are hazards present in troubleshooting that can cause equipment damage, se-

Possible Cause Corrective Action

1. Emergency Stop Switch OFF Push ON.

2. “Check Generator” or “Check En­gine” Fault

3. Faulty remote circuit Try starting at the genset control panel. If the genset starts,

Service the f a u l t a s necessary and push fault reset button in.
See “CHECK ENGINE” FAULT SHUTDOWN or “CHECK
GENERATOR” FAULT SHUTDOWN.

have the remote circuit repaired as necessary.

27

ENGINE DOES NOT CRANK FROM GENSET PANEL

WARNING

There are hazards present in troubleshooting that can cause equipment damage, se­vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

Possible Cause Corrective Action

1. Emergency Stop Switch OFF Push ON.

2. “Check Generator” or “Check En­gine” Fault

Service the f a u l t a s necessary and push fault reset button in.
See “CHECK ENGINE” FAULT SHUTDOWN or “CHECK
GENERATOR” FAULT SHUTDOWN.

3. Cranking voltage too low a. Clean and tighten or replace the positive (+) and negative (- )

battery cable connectors and cables at the battery and the
genset.

b. Recharge or replace the battery. Specific gravity for a fully

charged battery is approximately 1.260 at 80° F (27° C).

ENGINE CRANKS BUT DOES NOT START

WARNING

There are hazards present in troubleshooting that can cause equipment damage, se­vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

Possible Cause Corrective Action

1. Engine not getting fuel a. Open any closed shutoff valve.
b. Check fuel level and refill as necessary.
c. Prime the fuel system (p. 25).
d. Check for fuel (air) leaks at all fittings and tighten as neces-

sary.

e. Replace the fuel filter (p. 24).

2. Blocked air inlet Service as necessary.

28

ENGINE CRANKS BUT DOES NOT START(CONT.)

WARNING

There are hazards present in troubleshooting that can cause equipment damage, se­vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

Possible Cause Corrective Action

3. Low engine temperature a. Plug in, repair or install engine coolant and engine oil heat­ers.

b. Replace the engine oil if it is not of the recommended viscos-

ity for the ambient temperature.

4. Cranking voltage too low a. Clean and tighten or replace the positive (+) and negative (- )
battery cable connectors and cables at the battery and the
genset.

b. Recharge or replace the battery. Specific gravity for a fully

charged battery is approximately 1.260 at 80° F (27° C).

“CHECK ENGINE” FAULT SHUTDOWN

WARNING

There are hazards present in troubleshooting that can cause equipment damage, se­vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

Possible Cause Corrective Action

1. Low engine oil pressure Check engine oil level, repair any leaks and fill to the proper
level (p. 18).

2. High engine temperature a. Check engine coolant level, repair any leaks and fill to the
proper level (p. 19).

b. Check V-belt tension (p. 21).
c. Clean and service the cooling system as required to restore

full cooling capacity (p. 19).

3. High exhaust temperature a. Open the sea cock.

b. Remove any blockage in the sea water strainer.
c. Prime the sea water pump (p. 23).
d. Replace the sea water pump impeller (p. 23).
e. Clean seaweed and pump debris from heat exchanger

(p. 23).

f. Remove blockage covering the sea water hull strainer.

29

“CHECK GENERATOR” FAULT SHUTDOWN

WARNING

There are hazards present in troubleshooting that can cause equipment damage, se­vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

Possible Cause Corrective Action

1. Generator overload. Run with less load.

ENGINE LACKS POWER OR IS UNSTABLE

WARNING

vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

There are hazards present in troubleshooting that can cause equipment damage, se-

Possible Cause Corrective Action

1. Inadequate fuel delivery a. Check for fuel (air) leaks at all fittings and tighten as neces­sary.

b. Replace the fuel filter (p. 24).

2. Contaminated fuel Connect the fuel lift pump to a container of fuel of known
quality. Replace the contents of the fuel supply tank if there
is a noticeable difference in performance.

NO OUTPUT VOLTAGE

WARNING

vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.

There are hazards present in troubleshooting that can cause equipment damage, se-

Possible Cause Corrective Action

1. A line circuit breaker is Off. Find out why the circuit breaker was turned Off, make sure
it is safe to reconnect power, and then throw the circuit break­er On.

2. A line circuit breaker has

Tripped.

Shut down the genset and have service performed as neces­sary to clear the short circuit or ground fault that caused trip­ping. Then Reset the circuit breaker and start the genset.

30

How to Obtain Service

When you need parts or service for your genset
contact the nearest authorized dealer or distributor.
Onan has factory-trained representatives to handle
your needs for genset parts and service. To locate
the nearest authorized distributor:

1. Check the North American Sales and Service
Directory (F-118) and the International Sales
and Service Directory (IN-1013) supplied with
your Onan genset. These directories list autho­rized distributors who will assist you in locating
the nearest authorized dealer.

2. Consult th e Yellow Pages. T ypically, our distrib­utors are listed under:

GENERATORS - ELECTRIC,
ENGINES - GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES - EQUIPMENT,
PARTS AND SERVICE.

3. Call 1-800-888-ONAN for the name and tele­phone number of the nearest Cummins/Onan
or Onan-only distributor in the United States or
Canada. (This automated service utilizes

touch-tone phones only). By calling this num­ber you can also request a directory of autho­rized RV servicing dealers: RV Sales and Ser­vice Directory F-919.

,

To get service
tributor nearest you, explain the problem and make
an appointment. If you have difficulty in arranging
for service or resolving a problem, please contact
the dealer coordinator or service manager at the
nearest Cummins/Onan distributor for assistance.

Before calling for service, have the following infor­mation available:

1.

Complete model number and serial number

2.

Date of purchase

3.

Nature of the problem.

WARNING

contact the authorized dealer or dis-

Improper service or replacement of
parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
must be qualified to perform electrical and/or
mechanical service.

31

Maintenance Record

Use the following table to keep a record of all periodic and unscheduled maintenance and service. See

ic Maintenance.

HOUR

DATE

METER

READING

MAINTENANCE OR SERVICE PERFORMED

Period-

Record the name, address, and phone number of your authorized Onan service center.

32

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: [phone]

Cummins and Onan are registered trademarks of Cummins Inc.