Onan MDKBK, MDKBL, MDKBM, MDKBN, MDKBP Owner's Manual

Operator’s Manual

MDKBK MDKBL MDKBM MDKBN
MDKBP MDKBR MDKBS
MDKBT MDKBU

981-0175C
01-07

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

SECTION PAGE

SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Model Identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

How to Obtain Service 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emissions Label 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. CONTROL PANEL 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control and Monitoring 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Local Control Panel 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Display 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. OPERATION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine Coolant 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Batteries 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fire Extinguisher Port 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pre-Start Checks 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Priming the Fuel System 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Starting the Genset 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Stopping the Genset 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Emergency Stop 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Loading the Genset 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

No-Load Operation 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Resetting Line Circuit Breakers 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connecting to Shore Power 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold Temperature Operation 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Care of New or Re-Built Engine 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exercising the Genset 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Storing the Genset 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

SECTION PAGE

4. PERIODIC MAINTENANCE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Inspection 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Battery and Battery Connections 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . .

Checking Engine Oil Level 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Changing Engine Oil and Filter 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Draining/Replacing Fuel Filters 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maintaining the Engine Cooling System 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. TROUBLESHOOTING 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting with Digital Display 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting with Status Lamp 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6. SPECIFICATIONS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. MAINTENANCE RECORD 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is operated and maintained proper­ly.

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

DANGER

that will result in severe personal injury or
death.

WARNING

practice that can result in severe personal inju­ry or death.

CAUTION

practice that 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.

alerts you to an immediate hazard

alerts you to a hazard or unsafe

alerts you to a hazard or unsafe

• The genset must not be connected to shore
power or to any other source of electrical pow­er. Back-feed to shore power can cause elec­tric shock resulting in severe personal injury or
death and damage to equipment. 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, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.

DIESEL FUEL IS COMBUSTIBLE

• Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip­ment. Keep flames, sparks, pilot lights, arc­producing equipment and all other sources of
ignition well away.

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

ENGINE EXHAUST IS DEADLY

• Never sleep in the boat while the genset is run­ning unless the boat is equipped with properly
working carbon monoxide detectors.

• 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.

• Inspect for exhaust leaks every startup and af­ter every eight hours of operation.

• For more information about carbon monoxide
see American Boat and Yacht Council (ABYC)
publication TH-22—Educational Information

About Carbon Monoxide.

GENERATOR VOLTAGE IS DEADLY

• Generator electrical output connections must
be made by a trained and experienced electri­cian in accordance with applicable codes.

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,

and other moving parts.

BATTERY GAS IS EXPLOSIVE

• Wear safety glasses.

• Do not smoke.

• To reduce arcing when disconnecting or recon-

necting battery cables, always disconnect the
negative (−) battery cable first and reconnect
it last.

iii

FLAMMABLE VAPOR CAN CAUSE A

DIESEL ENGINE TO OVERSPEED

• Keep the genset, drip pan and compartment
clean. Oily rags can catch fire. Gear stowed in
the compartment can restrict cooling.

Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. Do not operate a diesel-powered genset

where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and

operators of the genset are solely responsible for
operating the genset safely.

GENERAL PRECAUTIONS

• Keep children away from the genset.

• Do not use evaporative starting fluids. They

are highly explosive.

• Do not step on the genset when entering or
leaving the generator room. Parts can bend or
break leading to electrical shorts or to fuel,
coolant or exhaust leaks.

• To prevent accidental or remote starting while
working on the genset, disconnect the nega­tive (−) battery cable at the battery.

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

• Make sure all fasteners are secure and proper­ly torqued.

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

• You must be trained and experienced to make
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
U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.

• Ethylene glycol, used as engine coolant, is tox­ic to humans and animals. Clean up spills and
dispose of used engine coolant in accordance
with local environmental regulations.

• Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus­tible materials such as wood and cloth; Class B
fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)

• Genset installation and operation must comply
with all applicable local, state and federal
codes and regulations.

POST THESE SAFETY PRECAUTIONS IN POTENTIAL

HAZARD AREAS OF THE BOAT

M-10

iv

1. Introduction

ABOUT THIS MANUAL

This is the Operator’s Manual for the generator sets
(gensets) listed on the front cover. Each operator
should study this manual carefully and observe all of
its instructions and safety precautions. Keep this
manual close at hand for reference.

WARNING

tem. It can stop without warning. Children, per­sons with physical or mental limitations, and
pets could suffer personal injury or death. A per­sonal attendant, redundant power or alarm sys­tem must be used if genset operation is critical.

Operation, Periodic Maintenance and Trouble­shooting provide the instructions necessary for op-

erating the genset and maintaining it at top perfor­mance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (p. 4-1). This manual
also includes genset specifications, information on
how to obtain service, and information regarding
compliance with emissions regulations.

See the Parts Manual for part identification numbers
and required quantities. Genuine Onan® replace­ment parts are recommended for best results.

This genset is not a life support sys-

MODEL IDENTIFICATION

Be ready to provide the genset model and serial
numbers on the nameplate when contacting Onan
for parts, service and product information. Fig­ure 1-1 illustrates the nameplate and its location on
the side of the control box. Every character in these
numbers is significant. (The last character of the
model number is the specification letter, which is im­portant for obtaining the right parts.) Record the
genset model and serial numbers on the lines desig­nated in the figure so that they are easy to find when
you need them.

WARNING

parts can lead to severe personal injury or death
and to damage to equipment and property. Ser­vice personnel must be qualified to perform
electrical and mechanical service.

Improper service or replacement of

MODEL NUMBER: ______________________

SERIAL NUMBER: ______________________

FIGURE 1-1. TYPICAL NAMEPLATE

1-1

HOW TO OBTAIN SERVICE

EMISSIONS LABEL

For genset parts, service, and product information
(such as the Service Manual), contact the nearest
authorized Cummins/Onan distributor. You may go
to Internet site www.onan.com for information for
contacting our distributors worldwide.

In North America

Call 1-800-888-ONAN for the nearest Cummins/
Onan distributor in the United States or Canada.
Press 1 (OPTION 1) to be automatically connected.

If you are unable to contact a distributor using the
automated service, consult the Yellow Pages. Typi­cally, our distributors are listed under:

GENERATORS − ELECTRIC

Outside North America

Call Cummins Power Generation at
1−763−574−5000 from 7:30 AM to 4:00 PM (Cen­tral Standard Time), Monday through Friday, or fax
1−763−528−7229.

The label that states compliance with applicable en­gine emissions regulations is located on the engine
as circled in Figure 1-2. Refer also to the FEDERAL
EMISSION DESIGN AND DEFECT LIMITED WAR­RANTY FOR C. I. ENGINES (DIESELS) that was
shipped in the same package as the Operator’s
Manual.

Information To Have Available

1. Model Number, including Spec Letter, and Seri-

al Number (Figure 1-1).

2. Date of purchase.

3. Nature of problem (Section 5. Troubleshoot-

ing).

FIGURE 1-2. TYPICAL EMISSIONS LABEL

LOCATIONS

1-2

2. Control Panel

REMOTE CONTROL AND MONITORING

Remote e-Series Digital Displays and
Control Switches

The boat may be equipped with several remote gen­set control stations having either an e-Series Digital
Display or control switch.

Boat Monitoring System

The boat may also be equipped to monitor genset
operation on an integrated monitoring system using
an SAE J1939 or SmartCraft™ network protocol.

LOCAL CONTROL PANEL

Refer to Figure 2-1.

Control Switch Panel (Standard)

Control Switch: This switch is used to start and
stop the genset and prime fuel.

• Push and Hold START to preheat, crank and
start the genset. The green lamp comes on
when the genset is running. (Preheat is the pe­riod of time prior to engine cranking when the
glow plugs preheat the combustion chambers.
The time is automatically varied by the genset
controller on the basis of engine temperature.)

• Push and Release STOP (Prime) to stop the
genset.

• Push and Hold STOP (Prime) to prime the fuel
system (amber lamp comes on in 2 seconds to
indicate priming).

Status Lamps: The control switch has two status
lamps. The amber status lamp comes on during
priming, blinks rapidly during cranking and goes out
when the engine is up to speed. If the genset shuts
down abnormally, this lamp will slowly blink a nu­merical code to indicate the cause of shutdown. See
Troubleshooting (Section 5). The green status lamp
comes on to indicate that the genset is running.

Emergency Stop Switch: In an emergency push
the switch to OFF. Push it to ON after all necessary
repairs to the genset and connected equipment
have been made.

DC Circuit Breaker: This circuit breaker protects
the DC control circuits of the genset from short cir­cuits. Reset after all necessary repairs have been
made to the genset.

Hour Meter: The hour meter records genset operat­ing time in hours. It cannot be reset.

e-Series Digital Display Panel (Optional)

The control panel may have an e-Series Digital Dis­play instead of a control switch. See Page 2-3 for
details.

SmartCraft is a trademark of the Brunswick Corporation.

2-1

OPTIONAL DIGITAL

DISPLAY PANEL

STANDARD CONTROL

SWITCH PANEL

EMERGENCY

STOP SWITCH

DC CIRCUIT

BREAKER

DC CIRCUIT

BREAKER

EMERGENCY

STOP SWITCH

DIGITAL DISPLAY

HOUR

METER

CONTROL SWITCH

WITH STATUS LAMPS

FIGURE 2-1. GENSET CONTROL PANEL

2-2

DIGITAL DISPLAY

The e-Series Digital Display has an LCD screen
with 4 navigation buttons, 3 status lamps, a START
button and a STOP button (Figure 2-2).

Turning On the Display

Touch any button to turn on the Display, which will
initialize and establish communications with the
genset controller. All connected Displays will turn on
automatically when the genset is started at any sta­tion. They will all turn off 5 minutes after the genset
has received a normal command to stop. If a fault
occurs, they will stay on until the fault is cleared by
touching any button on any Display.

Start Button

Starting the Genset: Push and Hold START until
the genset starts. The GENSET status lamp blinks
while the engine is preheating and cranking. It
comes on when the genset starts and stays on while
it runs. The status displayed on the LCD changes
from Starting to Running (Figure 2-3). See START­ING THE GENSET (p. 3-3).

FIGURE 2-2. DIGITAL DISPLAY

Stop Button

Stopping the Genset: Push and Release STOP.
The GENSET status lamp will go out. The status
displayed on the LCD will change from Running to
Stopped (Figure 2-3). See STOPPING THE GEN­SET (p. 3-3).

Priming the Fuel System: Push and Hold STOP.
The GENSET status lamp will blink. The status dis­played on the LCD will change to Priming in 2 sec-
onds (Figure 2-3). See PRIMING THE FUEL SYS­TEM (p. 3-3).

Genset Status Lamps

GENSET − This status lamp (green) blinks while the

engine is cranking or the fuel system is being
primed. It stays on while the genset is running.

PRE-ALARM − This status lamp (amber) comes on
when an engine Pre-Alarm condition exists
(p. 2-6).

ALARM − This status lamp (red) blinks during fault
shutdown (p. 2-5).

2-3

Genset Status

Genset status is displayed on 3 screen pages (Fig­ure 2-3). GEN STATUS PG1 appears when the Dis­play is turned on. Press the double arrows [
toggle between the 3 screen pages.

The Status line on PG1 will display the word Prim-
ing, Starting, Running, Stopped, or Volt Adj. The
rest of the lines on the 3 status screen pages display
AC output voltage, AC frequency, engine coolant
temperature, engine oil pressure, starting battery
voltage and total genset running time.

] to

To

Fig. 2-7

To

Fig. 2-5

To

Fig. 2-8

FIGURE 2-3. TYPICAL GENSET STATUS SCREENS

2-4

Fault Screen

If a fault shutdown occurs the ALARM status lamp
will blink and the LCD screen will display the Fault
Number, a description of the Fault and the hour in
total genset running time when the Fault occurred
(Figure 2-4). Refer to TABLE 5-1. TROUBLE­SHOOTING GENSET FAULTS to diagnose and
correct the problem.

The e-Series Digital Display will display the fault in­definitely. Touch any button to clear the fault. The
display will turn off in 5 minutes after the fault has
been cleared.

FIGURE 2-4. TYPICAL FAULT SCREEN

Press [
screen.

BACK] to go back to the GEN STATUS

2-5

Fault History

To display any of the last five faults, press the FAULT
button on any GEN STATUS screen. Then press the
HIST button on the FAULT screen (Figure 2-5).

The FAULT HISTORY screen will display the last
Fault Number, a description of the Fault and the
hour in total genset running time when the fault oc­curred. Press the double arrows [

] to toggle be­tween the last 5 faults. If there are no faults, the
FAULT HISTORY screen will display No Stored
Faults.

Press [ BACK] to go back to GEN STATUS.

Engine Pre-Alarms

From FAULT, Fig. 2-3

The PRE-ALARM status lamp will come on when
engine oil pressure or temperature approaches its
limit for engine shutdown. The Display will display
Low Oil Pressure or High Engine Temperature on
the PRE-ALARM screen (Figure 2-6).

Press [

BACK] to go back to GEN STATUS to moni-

tor the engine temperature or oil pressure.

Service the genset as required.

OR

FIGURE 2-5. FAULT HISTORY

From FAULT, Fig. 2-3

OR

FIGURE 2-6. ENGINE PRE-ALARMS

2-6

Brightness and Contrast

To adjust the brightness and contrast of the LCD
screen and status lamps, go to the SCREEN AD­JUST screen by pressing SCREEN on any GEN
STATUS screen. Press NEXT to select Brightness
or Contrast . Increase or decrease the selected item
by pressing the increase-decrease buttons [
See Figure 2-7. (“Contrast” applies only to the LCD
screen.)

].

From SCREEN, Fig. 2-3

Press [

BACK] to save the settings and go back to

GEN STATUS.

Display Setup

Go to the SETUP screen by pressing SETUP on any
GEN STATUS screen. Press the up-down arrows

] to select Display Setup and press ENTER.

[
See Figure 2-8.

Units: To change the units of measure on the GEN
STATUS screens, press NEXT to select Units. Then
press the up-down arrows [
Metric and SAE units.

Press [

BACK] to save the selection and go back to

GEN STATUS.

AC Voltmeter Calibration: To calibrate the Display
Voltmeter, press NEXT to select AC Voltmeter
Calibration. Then press the up-down arrows [
to increase or decrease the voltage displayed to
correspond to an accurate AC output voltmeter
(line-to-line or line-to-neutral, as desired).

] to toggle between

]

FIGURE 2-7. SCREEN BRIGHTNESS & CONTRAST

From SETUP, Fig. 2-3

Press [

BACK] to save the selection and go back to

GEN STATUS.

Note:This procedure does not change AC output
voltage. Have a trained and experienced person ad­just AC output voltage, if necessary, before calibrat­ing the Display Voltmeter.

Genset and Display Information

Go to the SETUP screen by pressing SETUP on any
GEN STATUS screen. Press the up-down arrows
[ ] to select Genset Info or Display Info and press
ENTER. See Figure 2-8. This information may be
requested by the service technician.

Keep pressing [
TUS.

BACK] to get back to GEN STA-

FIGURE 2-8. SETUP, GENSET & DISPLAY INFO

2-7

This side is intentionally blank

3. Operation

FUEL

WARNING

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 multi­class ABC fire extinguisher handy.

High quality Grade 2-D diesel fuel is necessary for
good performance and long engine life. Diesel fuels
specified by EN 590 or ASTM D975 are recom­mended. Use Grade 1-D diesel fuel if the fuel tank is
exposed to temperatures below 40° F (5° C).

The Cetane number should not be less than 45 and
sulfur content 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° F
(6° C) degrees below the lowest expected fuel tem­perature.

Fuel lubricity should pass a minimum load level of
3100 grams as measured by ASTM D6078 or maxi­mum scar diameter of 0.45 mm as measured by
ASTM D6079 or ISO 12156-1.

Note:Ultra Low Sulfur Diesel (ULSD) fuel that meets
the ASTM D975 standard for lubricity is suitable for
use with this engine. The 1 to 2 percent less energy
content of the fuel can have a slight effect on maxi­mum engine power.

Note:B5 Bio-Diesel fuel that meets industry specifi­cations and quality is suitable for use with this en­gine.

Diesel fuel is combustible and can

ENGINE OIL

Use API (American Petroleum Institute) Service
Category CI-4 engine oil or better. Also look for the
SAE (Society of Automotive Engineers) viscosity
grade. Referring to Figure 3-1, choose the viscosity
grade appropriate for the ambient temperatures ex­pected until the next scheduled oil change. Multi­grade oils such as SAE 15W-40 are recommended
for year-round use.

FIGURE 3-1. OIL VISCOSITY GRADE VS. AMBIENT

TEMPERATURE

ENGINE COOLANT

Use the best quality ethylene glycol antifreeze solu­tion available. It should be a fully formulated with
rust inhibitors and coolant stabilizers. A 50/50 mix­ture of water and ethylene glycol is recommended to
provide protection from freezing down to -34
(-37

° C).

Use fresh water that is low in minerals and corrosive
chemicals for the coolant mixture. Distilled water is
best.

See Specifications (Section 6) regarding coolant
capacity.

WARNING

sidered toxic. Dispose of it according to local
regulations for hazardous substances.

Ethylene Glycol antifreeze is con-

° F

BATTERIES

Reliable genset starting and starter service life de­pend upon adequate battery system capacity and
maintenance. See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 4-2) and
Specifications (Section 6).

3-1

FIRE EXTINGUISHER PORT

A genset with an enclosure has a fire extinguisher
port accessible by breaking through the circle on the
warning label located as shown in Figure 3-2. 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 enclosure.

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.

FIGURE 3-2. FIRE EXTINGUISHER PORT

3-2

PRE-START CHECKS

WARNING

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

• Dizziness • Headache

• Nausea • Weakness and Sleepiness

• Vomiting • Inability to Think Coherently

GET EVERYONE OUT INTO FRESH AIR IMMEDI­ATELY IF ANYONE EXPERIENCES ANY OF
THESE SYMPTOMS. Seek medical attention if
symptoms persist. Never sleep in the boat when
the genset is running, unless the cabin has a
working carbon monoxide detector.

Look over the entire exhaust system and listen
for leaks every time you start up the genset and
after every eight hours of operation. Shut down
the genset immediately if there is a leak. Do not
run the genset until the leak has been repaired.
The exhaust system must be installed in accor­dance with the genset Installation Manual.

Before the first start of the day and after every eight
hours of operation, inspect the genset as instructed
under GENERAL INSPECTION (p. 4-2). Keep a log
of maintenance and the hours run and perform any
maintenance that may be due. See Returning the
Genset to Service (p. 3-6) if the boat has been in
storage. Before each start:

1. Make sure all CO detectors on board are work­ing properly.

2. Check for swimmers that might be exposed to
the engine exhaust.

3. Disconnect all electrical loads and disengage
the PTO (if so equipped).

EXHAUST GAS is deadly. All en-

PRIMING THE FUEL SYSTEM

STARTING THE GENSET

The genset can be started and stopped from the
genset control panel or remote control panel.

1. Push and Hold START on the e-Series Digital
Display or control switch until the genset starts.
The genset status lamp blinks when the engine
is cranking and comes on and stays on when
the genset starts and runs. The status dis­played on the e-Series Digital Display changes
from Starting to Running (Figure 2-3).

2. For longer engine life, let the engine warm up
for two minutes before connecting air condi­tioners and other large electrical loads or en­gaging the PTO (if so equipped).

3. Check for water, coolant, fuel and exhaust
leaks. Stop the genset immediately if there is a
leak. Repair fuel leaks immediately.

4. Monitor generator set status using the e-Series
Digital Display (p. 2-4), if so equipped. Perform
maintenance or service as necessary if the Dis­play indicates a Pre-Alarm condition (p. 2-3).

5. If the genset fails to start, cranking will dis-
continue in 20 to 60 seconds, depending on en­gine temperature. The e-Series Digital Display
and/or control switch status lamp will indicate
Fault Code No. 4. See Troubleshooting (Sec-
tion 5) if the genset does not start after several
tries.

CAUTION

Do not continue cranking and
risk burning out the starter or flooding the
engine (exhaust flow during cranking is too
low to expel water from a wet exhaust sys­tem). Find out why the genset does not start
and make necessary repairs.

6. If the genset shuts down, the e-Series Digital
Display and/or control switch status lamp will
indicate the numeric fault code. See Trouble-
shooting (Section 5).

STOPPING THE GENSET

Disconnect all electrical loads and disengage the
PTO (if so equipped) to let the genset run without
load and cool down. After 2 minutes Push and Re-
lease STOP on the e-Series Digital Display or con­trol switch. The genset status lamps will go out.

The fuel system should be primed after replacing
the fuel filter or running the genset out of fuel. To
prime the fuel system, Push and Hold STOP on the
e-Series Digital Display or STOP (Prime) on the
control switch for at least 30 seconds.

EMERGENCY STOP

Push the EMERGENCY STOP SWITCH to OFF
(p. 2-1). After all necessary repairs have been
made, push the switch to ON so that the genset can
be operated.

3-3

LOADING THE GENSET

How much equipment load can be powered de­pends upon the genset power rating. The genset will
shut down or its AC output circuit breakers will trip if
the sum of the loads exceeds genset power or cir­cuit breaker 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
with the power rating of the genset. Use Table 3-1 or
the ratings on the appliances themselves to obtain
the individual appliance loads. If the appliance is
marked in amps and volts only, multiply the amps
times the volts to obtain the appliance load (watts).

It may be necessary to run fewer appliances at
the same time—the sum of the loads must not
be greater than genset rating.

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

when large motors and air conditioners are cycl­ing on and off.

On gensets so equipped, the PTO can take most, if
not all, of the power available from the engine. The
boat builder may have made provisions to automati­cally disconnect all or most electrical loads when the
PTO is engaged. It may be necessary to run fewer

electrical loads—or none at all—when the PTO
is engaged.

The genset is rated at standard barometric pres­sure, humidity and temperature (ref. ISO 3046). Ei­ther low barometric pressure (high altitude) or high
ambient temperature will decrease engine power. It

may be necessary to run fewer loads under such
conditions.

TABLE 3-1. TYPICAL APPLIANCE LOADS

Appliance Load (watts)

Air Conditioner 1400-2000

Battery Charger Up to 3000

DC Converter 300-700

Refrigerator 600-1000

Microwave Oven 1000-1500

Electric Frying Pan or 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

3-4

NO-LOAD OPERATION

Keep no-load operation to a minimum. During

no-load operation cylinder temperatures drop to the
point where fuel does not burn completely, causing
fuel wetting and white smoke. It is best to run the
genset at 1/4 to 3/4 load.

RESETTING LINE CIRCUIT BREAKERS

If the genset line circuit breaker trips, or circuit
breaker in the power distribution panel of the boat,
either a circuit shorted or too many loads were con­nected. Note that the genset will continue to run af­ter a line circuit breaker trips.

If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break­er. 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 loads
one-by-one up to a total load that does not overload
the genset or cause the circuit breaker to trip. The
circuit probably has a short if the circuit breaker trips
right away when it is connected.

LINE CIRCUIT BREAKER HANDLES

PULL FORWARD FOR ON

Electrical equipment must be used and maintained
properly and be properly grounded to cause the line
circuit breakers to trip when short circuits occur.

WARNING

Short circuits in electrical equip­ment can cause fire and electrical shock leading
to severe personal injury or death. Electrical
equipment and its grounding must be main­tained properly to protect against short circuits.

CONNECTING TO SHORE POWER

When provisions have been made for connecting
shore power, the boat must have an approved de­vice to keep the genset and shore power from being
interconnected.

WARNING

shore power can lead to electrocution of utility
line workers, equipment damage and fire. Use
an approved switching device to prevent inter­connections.

Interconnecting the genset and

FIGURE 3-3. TYPICAL LINE CIRCUIT BREAKERS

3-5

COLD TEMPERATURE OPERATION

Drain the heat exchanger (p. 4-8) and muffler be­fore cold weather sets in if the genset is not being
used. Freezing water can damage the muffler and
the raw water tubes in the heat exchanger.

4. Disconnect the battery cables (negative [−]
cable first) from the starting battery and store
the battery according to the battery manufac­turer’s recommendations. See MAINTAINING
THE BATTERY AND BATTERY CONNEC­TIONS (p. 4-2).

CARE OF NEW OR RE-BUILT ENGINE

Avoid no-load operation as much as possible during
break-in. Change the oil and oil filter after the first 50
hours of operation (p. 4-3).

EXERCISING THE GENSET

Exercise the genset at least 1 hour every month if
use is infrequent. Run the genset at 1/4 to 3/4 load.
A single exercise period is better than several short­er periods. Exercising a genset drives off moisture,
re-lubricates the engine, uses up fuel before it be­comes stale and removes oxides from electrical
contacts. The result is better starting, more reliable
operation and longer engine life.

STORING THE GENSET

Proper storage is essential for preserving top gen­set performance and reliability when the genset
cannot be exercised regularly and will be idle for
more than 120 days.

Storing the Genset

1. Turn off the genset line circuit breaker.

2. Change the engine oil and filter and attach a tag
indicating oil viscosity. See ENGINE OIL REC­OMMENDATIONS (p. 3-1).

3. Crank the engine several revolutions but do not
let it start. This will fill the oil passages with the
new oil.

5. Check coolant level and add as necessary
(p. 4-7). Test the coolant mixture if freezing
temperatures are possible and change if nec­essary.

WARNING

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

6. Drain the heat exchanger and muffler if freezing
temperatures are expected.

7. Disengage a PTO clutch if so equipped.

8. Clean and lightly oil parts that can rust.

Hot coolant is under pressure

Returning the Genset to Service

1. Check the oil tag on the genset and change the
oil if the viscosity indicated is not appropriate for
the temperatures expected. See ENGINE OIL
RECOMMENDATIONS (p. 3-1).

2. Reconnect the starting battery (negative [−]
cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 4-2).

3. Replace the raw water pump impeller if it was
installed more than a year ago (p. 4-12).

4. Perform the maintenance required (p. 4-1),
conduct the pre-start checks and prime the fuel
system.

5. Start and run the genset.

6. Turn on the genset line circuit breaker when
ready to power loads.

3-6

4. Periodic Maintenance

Periodic maintenance is essential for top perfor­mance and long genset life. Use Table 4-1 as a
guide for normal periodic maintenance.

Maintenance, replacement or repair of emission
control devices and systems may be performed by
any engine repair establishment or individual. How­ever, warranty work must be completed by an au­thorized Onan service representative.

TABLE 4-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE OPERATION

General Inspection

1

After

First

50 Hrs

Every

Day /
8 Hrs

•

Check Engine Oil Level •

Drain Water from Fuel Filter •

To help you keep genset maintenance regular and
provide a basis for warranty claims, record mainte­nance performed in Maintenance Record (Sec-
tion 7).

WARNING

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

MAINTENANCE FREQUENCY

Every

Month/

100
Hrs

Every

Year/

200

Hrs

Every

Year/

350
Hrs

Every

Year/

500
Hrs

Every

800
Hrs

Every

Years

Every

5

Years/

2

2000

Hrs

Page

4-2

4-3

4-6

Inspect Battery and Battery Connec-

2

tions

Check V-Belt Tension

3

•

•

Inspect Siphon Break •

Change Engine Oil and Oil Filter—

All except MDKBT &MDKBU

Change Engine Oil and Oil Filter—

Only MDKBT &MDKBU

• •

• •

Replace Fuel Filters •

Inspect Zinc Anode •

Replace Raw Water Impeller •

Adjust Engine Valve Lash

Replace Coolant, Pressure Cap &
Thermostat

Inspect Generator Bearing

1 − Includes inspection of Oil Level, Coolant Level, Fuel System, Exhaust System, Batteries and Battery Connections.
2 − See battery manufacturer’s recommendations.
3 − Check for slippage, cracking and wear.
4 − Must be performed by a qualified mechanic (authorized Onan dealer).

4

•

•

4

•

4-2

4-13

4-8

4-3

4-3

4-6

4-8

4-12

−

4-7

−

4-1

GENERAL INSPECTION

Inspect the genset before the first start of the day
and after every eight hours of operation.

Oil Level

Check engine oil level (p. 4-3).

Exhaust System

vided (see Installation Manual), open the sea valve
for the water drain hose.

Check for and replace hoses that leak or are dam­aged.

Battery Connections

See MAINTAINING THE BATTERY AND BATTERY
CONNECTIONS.

Inspect the 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.

Check that all CO monitors are working properly.

WARNING

operate the genset until all exhaust leaks have
been repaired.

EXHAUST GAS IS DEADLY! Do not

Fuel System

Check for leaks at hose, tube and pipe fittings in the
fuel supply and return systems while the genset is
running and while it is stopped. Check flexible fuel
hose for cuts, cracks, abrasions and loose hose
clamps. Make sure fuel lines do not rub against oth­er parts. Replace worn or damaged fuel line parts
before leaks occur. Replace hose with with USCG
TYPE A1 or ISO 7840-A1 fuel hose.

Prime the fuel system if the genset ran out of fuel.

WARNING

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

Fuel leaks can lead to fire. Repair

Coolant Level

Check coolant level in the recovery tank and, if nec­essary, refill the recovery tank to COLD when the
engine is cold or to HOT when it is at normal running
temperature. The recovery tank is designed to
maintain coolant level, not to fill the system. If the
tank is empty, check for and repair any coolant leaks
and refill the system through the fill neck on the en­gine. See Refilling the Cooling System (p. 4-8).
Use the recommended antifreeze mixture (p. 3-1).

Mechanical

Monitor generator set status using the e-Series Dig-
ital Display (p. 2-4).

Look for mechanical damage and listen for unusual
noises when the genset is running. Check the gen­set mounting bolts. Check to see that the genset air
inlet and outlet openings are not clogged with debris
or blocked. Keep the genset compartment clean.

MAINTAINING THE BATTERY AND

BATTERY CONNECTIONS

WARNING

light switches or other equipment, and flames or
sparks, can ignite battery gas causing severe
personal injury—Ventilate battery area before
working on or near battery—Wear safety
glasses—Do not smoke—Switch work light ON
or OFF away from battery—Stop genset and dis­connect charger before disconnecting battery
cables—Disconnect negative (−) cable first and
reconnect last.

Refer to Table 4-1 for scheduled battery mainte­nance, and follow the battery manufacturer’s in­structions. Have the battery charging system ser­viced if DC system voltage is consistently low or
high.

Check the battery terminals for clean, tight connec­tions. Loose or corroded connections have high
electrical resistance which makes starting harder.
Always:

1. Keep the battery case and terminals clean and
dry and the terminals tight.

2. Remove battery cables with a battery terminal
puller.

Arcing at battery terminals or in

Raw Water System

Clean out the sea water strainer if necessary and
make sure the sea valve is open for genset opera­tion. Also, when a water/exhaust separator is pro-

3. Make sure which terminal is positive (+) and
which is negative (−) before making battery
connections, always removing the negative (−)
cable first and reconnecting it last to reduce
arcing.

4-2

CHECKING ENGINE OIL LEVEL

WARNING

termined that contact with used engine oil can
cause cancer or reproductive toxicity. Avoid
skin contact and breathing of vapors. Use rub­ber gloves and wash exposed skin.

CAUTION

gine damage. Too much oil can cause high oil
consumption.

Shut off the genset and check the oil level with the
dip stick (Figure 4-1, 4-2 or 4-3). Add or drain oil as
necessary. Add 1 quart (0.9 liters) when the level
falls to the ADD mark. Drain oil if the level is above
the full mark.

See ENGINE OIL RECOMMENDATIONS (p. 3-1).

State and federal agencies have de-

Too little oil can cause severe en-

CHANGING ENGINE OIL AND FILTER

Refer to Table 4-1 for scheduled engine oil change.

1. Run the genset under load until it is up to oper­ating temperature, stop it and disconnect the
negative (−) battery cable at the battery.

WARNING

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

Accidental or remote starting

2. Be ready to drain the oil into a suitable contain­er and then open the drain valve or unscrew the
plug on the end of the drain hose (Figure 4-1,
4-2 or 4-3) and drain the oil into a suitable con­tainer. (Two wrenches are necessary to keep
from twisting the hose when loosening and
tightening the plug.) If an oil pump-out system
is installed, follow the instructions provided.

3. Secure the drain plug or close the oil drain

valve.

4. Spin off the old oil filter with a filter wrench and
wipe off the filter mounting surface. (A filter
wrench is available from Onan.) Remove the
old gasket if it does not come off with the filter.

5. Apply a film of oil to the new filter gasket and
partly fill the new filter with oil so that it reaches
engine parts sooner at startup. Spin the filter on
by hand until the gasket just touches the mount­ing pad and tighten 3/4 turn.

6. Refill the engine with the proper type and
amount of engine oil. See ENGINE OIL REC­OMMENDATIONS (p. 3-1) and Specifications
(Section 6). Check the oil level and add or drain
oil as necessary. Run the engine for a few min­utes, shut it down and recheck for proper oil lev­el.

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

4-3

OIL DIPSTICK OIL FILL

OIL DRAIN

HOSE

FUEL FILTER AND

WATER SEPARATOR

OIl FILTER

FIGURE 4-1. OIL AND FUEL SERVICE POINTS—MDKBK, MDKBL, MDKBM, MDKBN

OIL DIPSTICK

OIL FILL

FIGURE 4-2. OIL AND FUEL SERVICE POINTS—MDKBP, MDKBR, MDKBS

FUEL FILTER AND

WATER SEPARATOR

4-4

OIl FILTER

FUEL FILTER OIL DIPSTICK OIL FILL

OIL FILTER

OIL DRAIN HOSE

FIGURE 4-3. OIL AND FUEL SERVICE POINTS—MDKBT, MDKBU

4-5

DRAINING/REPLACING FUEL FILTERS

WARNING

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 multi­class ABC fire extinguisher handy.

Keep dirt, water and other contaminants from enter­ing the fuel system and corroding or clogging fuel in­jection components.

Draining Water and Sediment: The genset may
have a water-separator type of fuel filter (Figure 4-1,
4-2). Also check for up-stream water-separator type
fuel filters. Drain water and sediment more often
than scheduled (Table 4-1) if fuel quality is poor or
condensation cannot be avoided. Dispose of the
water, sediment and fuel drained off in accordance
with local environmental regulations.

Diesel fuel is combustible and can

Replacing Fuel Filters: See Table 4-1 for sched-

uled fuel filter replacement. Replace fuel filters (Fig­ure 4-1, 4-2 or 4-3) if the engine lacks power.

1. Disconnect the negative (−) cable at the battery
to prevent the engine from starting and close
any fuel supply and return valves.

WARNING

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

2. Spin off the old filter with a filter wrench and dis­pose of it in accordance with local environmen­tal regulations.

3. Clean the contact surface on the filter base, lu­bricate the new filter gasket and spin the new
filter on hand tight.

4. Prime the engine for at least 30 seconds
(p. 3-3) to fill the new filter. Run the genset and
check for leaks. Tighten the filter by hand, if
necessary.

4-6

MAINTAINING THE ENGINE COOLING

SYSTEM

sure (10 psi) is essential for optimal engine cooling
and minimal coolant loss.

Refer to Table 4-1 for scheduled maintenance.

Cooling System Overview

The engine is cooled by a pressurized, closed-loop
liquid cooling system in which coolant is pumped
through passages in the engine block, head and ex­haust manifold (Figure 4-4, 4-5or 4-6). Heat is car­ried away from the coolant by a keel cooler or raw
water (sea water) heat exchanger. A gear-driven
raw water pump is provided if the genset has a heat
exchanger or wet exhaust.

Keel Cooler: A keel cooler, when provided, is part
of the pressurized, closed-loop liquid cooling sys­tem through which the coolant flows.

Heat Exchanger: When a heat exchanger is pro­vided, raw water (the floatation water) is pumped
through tubes in the heat exchanger to cool the en­gine coolant. The water is then passed through a
hose into the exhaust-water mixer to cool the ex­haust gases. The raw water is expelled from the
boat along with the exhaust gases.

Coolant Hoses

Check for and replace hoses that leak or are dam­aged.

Draining and Cleaning Cooling System

Have towels and containers ready to wipe up, col­lect and properly dispose of the coolant. Disconnect
the negative (−) cable at the battery to prevent the
engine from starting and let the engine cool before
removing the pressure cap.

WARNING

cause severe personal injury or death. Discon­nect the negative (−) cable from the battery to
prevent the engine from starting.

Hot coolant spray can cause severe burns. Let
the engine cool before releasing the pressure
cap or removing the drain cap.

Accidental or remote starting can

Recommended Coolant Mixture

See ENGINE COOLANT (p. 3-1) for recommenda­tions.

Replenishing Normal Coolant Loss

Check coolant level in the recovery tank before the
first startup of each day and, if necessary, refill to
COLD when the engine is cold or to HOT when it is
running. The recovery tank is designed to maintain
coolant level, not to fill the system. If the tank is
empty, check for and repair any coolant leaks and
refill the system through the fill neck on the engine.

Pressure Cap

Replace the pressure cap every two years (seals
deteriorate and leak). Proper cooling system pres-

Remove the pressure cap and open the block and
heat exchanger drain valves (Figure 4-4, 4-5or 4-6)
and drain the coolant into suitable containers for dis­posal in accordance with the local regulations for
hazardous substances.

Drain or flush a keel cooler in accordance with the
manufacturer’s instructions.

Use radiator cleaning chemicals to clean and flush
the cooling system before refilling with fresh cool­ant. Follow the cleaner manufacturer’s instructions.

CAUTION

can cause cracks in the manifold, head and
block. Follow the manufacturer’s instructions
for cleaning and flushing.

Filling a hot engine with cold water

4-7

Refilling Cooling System

Close the block and heat exchanger drain valves
and fill the system through the engine fill neck. 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 couple of minutes to dislodge air pockets and
shut it down. Add as much coolant as necessary
and secure the pressure cap. Then refill the recov­ery tank up to the COLD mark.

CAUTION

Low coolant level can cause severe

engine damage. Make sure the system is full.

Heat Exchanger

Both ends of the heat exchanger (Figure 4-4, 4-5 or
4-6) have raw water drain plugs and cleanout cov­ers. Clean the raw water tubes if the engine keeps
shutting down (Code No.1). Drain the heat ex­changer if there is a danger of freezing when the
genset is not running or is in storage. (Freezing wa­ter can damage the raw water tubes in the heat ex­changer. Engine coolant, but not raw water, is pro­tected from freezing.)

CAUTION

not overtighten the heat exchanger mounting
straps or the heat exchanger could be de-

Models MDKBT and MDKBU—Do

formed. Torque the strap screws as specified in
Figure 4-6.

Zinc Anode

Replace the zinc anode as recommended
(Table 4-1). Use thread sealant on the zinc plug and
drain plugs and replace the clean out cover gaskets
if the old ones are torn or otherwise damaged.

Siphon Break

See Table 4-1 for scheduled maintenance. A siphon
break is installed when the exhaust-water mixer is
below the water line. If of a 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 through-hull fit­ting, check for normal water flow whenever the en­gine is running. See the Installation Manual for more
information regarding siphon break installation.

WARNING

to maintain it can lead to engine flooding and
damage to the engine not covered under War­ranty.

Bypassing a siphon break or failing

4-8

OPTIONAL LOW COOLANT

LEVEL SENSOR LOCATION

COOLANT PUMP

RAW WATER PUMP

RAW WATER FLOW SENSOR

COOLANT

THERMOSTAT

BULKHEAD FITTING ON

RAW WATER IN FROM

RIGHT OR LEFT SIDE

EXHAUST MANIFOLD & COOLANT RESERVOIR

WITH PRESSURE CAP AND COOLANT FILL

NECK. FILL NECK HAS HOSE BARB FOR

CONNECTING COOLANT RECOVERY TANK

COOLANT

DRAIN

VALVE

ZINC

ANODE

BLOCK DRAIN VALVE

(COOLANT)

RAW WATER CLEANOUT

COVER (BOTH ENDS)

RAW WATER DRAIN PLUG

(BOTH ENDS)

EXHAUST-WATER MIXER

WITH HIGH TEMPERATURE

EXHAUST SWITCH

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT OR

LEFT SIDE

RAW WATER HOSE TO

EXHAUST-WATER

MIXER—WHEN REQUIRED,

REPLACE WITH SIPHON

BREAK AND CONNECTING

HOSES

COOLANT

COOLANT

RAW WATER

RAW WATER

FIGURE 4-4. ENGINE COOLING SYSTEM—MDKBK, MDKBL, MDKBM, MDKBN

4-9

RAW WATER TO PUMP FROM

BULKHEAD FITTING ON

RIGHT OR LEFT SIDE

RAW

WATER

PUMP

RAW WATER HOSE TO

EXHAUST-WATER

MIXER—WHEN REQUIRED,

REPLACE WITH SIPHON

BREAK AND CONNECTING

HOSES

COOLANT RESERVOIR WITH PRESSURE CAP AND

COOLANT FILL NECK. FILL NECK HAS HOSE BARB

FOR CONNECTING COOLANT RECOVERY TANK

RAW WATER FLOW SWITCH

(IN PUMP-TO-HEAT EXCHANGER HOSE)

LOCATION, OPTIONAL LOW

COOLANT LEVEL SENSOR

COOLANT

THERMOSTAT

HOUSING

COOLANT

TEMPERATURE

SENSOR

COOLANT

PUMP PULLEY

LOCATION, BLOCK

DRAIN VALVE

(COOLANT)

ZINC ANODE

COOLANT DRAIN VALVE

RAW WATER PLUGS

(UNDERNEATH)

FIGURE 4-5. ENGINE COOLING SYSTEM—MDKBP, MDKBR, MDKBS

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT

OR LEFT SIDE

RAW WATER CLEANOUT COVER

(BOTH ENDS—MAKE SURE TO

RECONNECT GROUND STRAP ON

THIS END WITH COVER SCREW)

EXHAUST-WATER MIXER

WITH HIGH TEMPERATURE

EXHAUST SWITCH

COOLANT

RAW WATER

4-10

ZINC

ANODE

HOSE, THERMOSTAT TO

COOLANT RESERVOIR

HOSE, RAW WATER TO

HOSE, RAW WATER TO

EXHAUST-WATER MIXER*

EXHAUST-WATER MIXER*

LOCATION,

RAW WATER

FLOW SWITCH

HOSE, COOLANT

RESERVOIR TO

HEAT EXCHANGER

HOSE, HEAT
EXCHANGER TO
COOLANT PUMP

HOSE, RAW WATER PUMP

TO HEAT EXCHANGER

HEAT EXCHANGER WITH CLEANOUT

COVERS, TOP & BOTTOM

HEAT EXCHANGER

MOUNTING STRAPS (2)

TORQUE TO 8 FT−LB (11 N-M)

COOLANT

DRAIN VALVE

RAW WATER
DRAIN PLUG

COOLANT

RAW WATER

RAW

WATER

PUMP

* Replace hose with siphon break and connecting hoses when
required. For dry exhaust replace with hose to hull fitting.

FIGURE 4-6. ENGINE COOLING SYSTEM HOSES, HEAT EXCHANGER, RAW WATER PUMP—MDKBT, MDKBU

4-11

Replacing Raw Water Pump Impeller

See Table 4-1 for scheduled replacement. Replace
the impeller as follows:

1. Close the sea valve.

2. Disconnect the negative (−) cable at the battery
to prevent the engine from starting.

WARNING

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

3. Loosen the three screws on the end of the
pump body to remove the pump body or impel­ler cover, depending on construction (Fig­ure 4-7).

4. Remove the impeller. An impeller removal tool
may be necessary to pull the impeller off the
shaft. Note: If vanes have broken off the impel-

ler, check for and cleanout pieces that may
have lodged in the heat exchanger.

5. Install the new impeller. To ease installation and
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. It also helps to
twist the impeller while squeezing it into the
housing.

MDKBP, MDKBR, MDKBS

MDKBK, MDKBL, MDKBM, MDKBN

CAUTION

Do not lubricate the impeller
with grease or oil or other petroleum prod­ucts because they are known to chemically
attack impeller materials.

6. Secure the cover or pump body and O-ring.

7. Fill the sea water strainer for faster priming at

startup if it is above the water line.

8. Open the sea valve, reconnect the battery
cables (negative [−] last) and start the genset.
The genset will shut down within a few seconds
if there is no raw water flow and Fault Code
No. 7 (p. 5-4) will be declared. If it shuts down,
find out why, remove any blockage and restart
the genset.

MDKBT, MDKBU

FIGURE 4-7. TYPICAL RAW WATER PUMPS

4-12

Adjusting V-Belt Tension

The V-belt drives the battery charging alternator and
coolant pump (Figure 4-8). See Table 4-1 for
scheduled inspection or replacement. Adjust belt
tension as follows:

1. Disconnect the negative (−) cable at the battery
to prevent the engine from starting.

WARNING

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

2. Remove the belt guard or enclosure top panel
and access doors.

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

4. Pivot the alternator out to tighten belt tension.
Hold tension by tightening the tension adjusting
bolt and then check tension by applying 20
pounds (10 kg) to the middle of the pulley span.
Belt tension is correct when deflection is
3/8 inch (10 mm). Tighten the alternator bolts
when tension is correct.

Accidental or remote starting

TENSION

ADJUSTING

BOLT

ALTERNATOR

PIVOT BOLT

3/8 INCH (10 MM)

DEFLECTION @

20 LBS (10 KG)

5. Tighten the bolts, secure the belt guard or en­closure and reconnect the battery cables (neg­ative [−] last).

Replacing V-Belt When PTO Equipped

A special belt replacement kit must be used when
the genset is equipped with a PTO. The kit includes
a tool to keep the flexible coupling from twisting dur­ing assembly/disassembly. The coupling has to be
disassembled so that the belt can be looped around
the crank pulley. Follow the instructions in the kit.

FIGURE 4-8. ADJUSTING V-BELT TENSION

4-13

Replacing the Thermostat

See Table 4-1 for scheduled replacement. Refer­ring to Figure 4-9, replace the thermostat as follows:

1. Disconnect the negative (−) cable at the battery
to prevent the engine from starting, let the en­gine cool and remove the front and back access
doors if the genset has an enclosure.

WARNING

ACCIDENTAL OR REMOTE
STARTING can cause severe personal inju­ry or death. Disconnect the negative (−)
cable from the battery to prevent the engine
from starting.

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

2. Remove the coolant pressure cap.

3. Remove the two thermostat housing bolts and
pull off the housing, thermostat and gasket. The
hose does not need to come off.

4. Clean off the gasket area and install the new
thermostat and gasket. Apply Three Bond 1215
liquid sealant or equivalent to the top side of the
gasket.

5. Replenish any lost coolant, secure the pres­sure cap and any doors and panels removed
and reconnect the battery cables (negative [−]
last).

THERMOSTAT

FIGURE 4-9. TYPICAL THERMOSTAT

4-14

5. Troubleshooting

Use TABLE 5-1. TROUBLESHOOTING GENSET
FAULTS in conjunction with the e-Series Digital Dis­play or blinking control switch status lamp to trouble­shoot the genset. Perform the step-by-step correc­tive actions suggested. If you are still unable to re­solve the problem, contact an authorized Onan ser­vice representative. See How to Obtain Service
(p. 1-2).

Note:Many genset shutdowns can be avoided by per­forming periodic maintenance on schedule
(TABLE 4-1. PERIODIC MAINTENANCE SCHEDULE)
and by not running the genset out of fuel. Note that
when gensets and propulsion engines draw from the
same fuel tanks, the fuel pickup tubes are usually ar­ranged so that the gensets run out of fuel first. By
marking the genset empty points on the fuel gauges,
it will be easier to tell when to stop the gensets before
running them out of fuel.

TROUBLESHOOTING WITH DIGITAL

DISPLAY

TROUBLESHOOTING WITH STATUS LAMP

If a fault shutdown occurs, the amber status lamp on
the control switch will repeatedly blink sets of 3, 4, 5
or 7 blinks.

• One blink indicates shutdown due to high en­gine temperature.

• Two blinks indicate shutdown due to low oil
pressure.

• Three blinks indicate a service fault. Press
Stop once to cause the two-digit shutdown

code to blink. (Pressing Stop again will stop the
blinking.) The two-digit code consists of 1 to 7
blinks, a brief pause, and then 1 to 9 blinks. The
first set of blinks represents the tens digit and
the second set of blinks the units digit of the
shutdown code number. For example, Low
Voltage Code No. 13 appears as: blink—

pause—blink-blink-blink—long pause—re­peat

• Four blinks indicate shutdown due to a failure
to start within the time allowed for cranking.

If a fault shutdown occurs the ALARM status lamp
on the e-Series Digital Display will blink and the LCD
screen will display the Fault Number, a description
of the Fault and the hour in total genset running time
when the Fault occurred (Figure 2-4).

The fault will be displayed until it is cleared. Touch
any button to clear the fault. The display will turn off
in 5 minutes after the fault has been cleared.

Last Five Faults: See Page 2-6 to display any of
the last five faults in fault history.

• Five blinks indicate shutdown due to high lev­els of Carbon Monoxide (CO) in the vessel.

• Seven blinks indicate shutdown due to a loss
of raw water flow for engine and exhaust cool­ing.

Blinking continues for five minutes and stops. To re­store blinking press the control switch to STOP
(Prime) until the lamp comes on (3 to 4 seconds).
Then press STOP (Prime) three times to restores
blinking.

Note:The last fault logged will blink even though the
condition that caused the shutdown may have been
corrected.

5-1

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS

WARNING

Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

NO RESPONSE AT DIGITAL DISPLAY OR CONTROL SWITCH

(Faulty switch, poor or missing connections, dead battery)

Corrective Action:

1. Push the Emergency Stop and/or DC Circuit Breaker ON if tripped.

2. Try the Digital Display or control switch on the genset (local) if there is no response at a remote Dis­play or control switch, and vice versa.

3. If none of the Displays or control switches works, service as necessary by cleaning and tightening
battery connections, recharging or replacing the battery or replacing damaged battery cables
(p. 4-2).

THE STARTER ENGAGES AND DISENGAGES

(Low cranking voltage)

Corrective Action:

1. De-energize the PTO clutch, if so equipped.

2. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).

THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE

(Marginal battery, battery connections or charging system)

Corrective Action:

1. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).

2. Check the V-belt that drives the charging alternator and service as necessary (p. 4-13).

3. Check for and disconnect parasitic battery loads.

NO AC POWER WHEN GENSET IS RUNNING

(A Circuit Breaker is OFF, tripped or malfunctioning or the generator is not connected properly)

Corrective Action:

1. Reset, turn ON or repair the genset circuit breaker, as necessary.

2. Reset, turn ON or repair any other circuit breaker in the AC power supply system, as necessary.

5-2

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS (CONT.)

WARNING

Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

HIGH ENGINE TEMPERATURE—CODE NO. 1

(Engine coolant temperature exceed design limit)

Corrective Action:

1. Check for and clean a blocked sea water strainer. If above the water line, fill the strainer with water
to assist priming.

2. Check engine coolant level and add coolant as necessary.

3. Check for kinked or leaking hoses and reconnect, reroute or replace.

4. Check the V-belt that drives the coolant pump and service as necessary (p. 4-13).

5. Inspect the siphon break for proper operation (p. 4-8).

6. Check for a worn raw water impeller and replace as necessary (p. 4-12).

7. Clean the heat exchanger (p. 4-8).

8. Check the bottom of the hull for any blockage at the through-hull fitting.

9. Replace the coolant thermostat, which might not be opening fully (p. 4-14).

10. Drain and clean the coolant system to remove coolant passage fouling (Page 4-7).

LOW OIL PRESSURE—CODE NO. 2

(Low oil pressure)

Corrective Action: Check the engine oil level and add or drain oil as necessary (p. 4-3). Repair any oil
leaks.

SERVICE CHECK—CODE NO. 3

(A fault with a 2-Digit Fault Code Number occurred)

Corrective Action: Check the 2-Digit fault code by Pushing and Releasing Stop. The 2-Digit fault will
be one of the following in this table. (Does not apply to e-Series Digital Display.)

OVERCRANK—CODE NO. 4

(Cranking time exceeded 20 to 60 seconds, depending on engine temperature)

Corrective Action:

1. De-energize the PTO clutch, if so equipped.

2. Check fuel level and refill as necessary. (Note: The genset fuel pickups are probably higher than the
propulsion engine fuel pickups.)

3. Open any closed fuel supply and return valves.

4. Prime the engine fuel system for at least 30 seconds (p. 3-3).

5. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).

6. Replace fuel filters (p. 4-6).

7. Check all fuel fittings for fuel and air leaks and tighten as necessary.

8. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.

5-3

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS (CONT.)

WARNING

Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

WARNING—SHUTDOWN DUE TO VESSEL CO—CODE NO. 5

(Dangerous levels of Carbon Monoxide in Vessel)

Corrective Action: Get everyone out into fresh air immediately and seek medical attention.

LOSS OF RAW WATER FLOW—CODE NO. 7

(Low raw water pressure in heat exchanger)

Corrective Action:

1. Open the sea cock.

2. Check for a blocked sea water strainer and clean it out. If above the water line, fill the strainer with
water to assist priming.

3. Check for kinked or leaking hoses and reconnect, reroute or replace.

4. Check for a worn raw water impeller and replace as necessary (p. 4-12).

5. Check the bottom of the hull for any blockage at the through-hull fitting.

HIGH AC VOLTAGE—CODE NO. 12

(After voltage regulation was enabled Output Voltage jumped to more than 125% of rated for 75 millisec-

onds or to more than 115% of rated for 3 seconds)

Corrective Action:

1. Check for a tripped genset circuit breaker, reset if necessary, and run with fewer loads. (A breaker
tripping under load can cause genset voltage to overshoot.)

2. Check all fuel fittings and filters for fuel and air leaks and tighten as necessary. (Air bubbles can
disrupt genset voltage.)

3. Prime the engine fuel system for at least 30 seconds (p. 3-3).

LOW AC VOLTAGE—CODE NO. 13

(After voltage regulation was enabled Output Voltage fell to less than 90% of rated for 5 seconds)

Corrective Action:

1. Push the genset line circuit breaker OFF and disconnect the PTO, if so equipped. If the genset
now runs and voltage and frequency are normal, reduce the number of electrical and mechanical
(PTO) loads.

2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)

3. Check all fuel fittings and filters for fuel and air leaks and tighten as necessary. (Air bubbles can
disrupt genset voltage.)

4. Replace fuel filters (p. 4-6).

5-4

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS (CONT.)

WARNING

Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

HIGH AC FREQUENCY—CODE NO. 14

(After the starter was engaged Frequency jumped to more than 70 Hz

for 40 milliseconds or to more than 2% over nominal for 6 seconds)

Corrective Action:

1. Check for a tripped genset circuit breaker, reset if necessary, and run with fewer loads. (A breaker
tripping under load can cause genset frequency to overshoot.)

2. Check all fuel fittings and filters for fuel and air leaks and tighten as necessary. (Air bubbles can
disrupt frequency.)

LOW AC FREQUENCY—CODE NO. 15

(During normal operation Frequency fell to less than 90% of nominal for more than 8 seconds)

Corrective Action:

1. Push the genset line circuit breaker OFF and de-energize the PTO clutch, if so equipped. If the
genset now runs, reduce the number of electrical and mechanical (PTO) loads, especially those with
high motor starting loads, such as air conditioners.

2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)

3. Prime the engine fuel system for at least 30 seconds (p. 3-3).

4. Check all fuel fittings for fuel and air leaks and tighten as necessary. (Air bubbles can disrupt fre­quency.)

5. Replace fuel filters (p. 4-6).

6. Remove combustion air or exhaust system blockages.

GOVERNOR OVERLOAD—CODE NO. 22

(Maximum allowable time at full-duty cycle was exceeded)

Corrective Action:

1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.

2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)

3. Check all fuel fittings for fuel and air leaks and tighten as necessary.

4. Replace fuel filters (p. 4-6).

5. Remove combustion air or exhaust system blockages.

FAULTY OIL PRESSURE SENDER—CODE NO. 23

(Controller sensed grounded sender)

Corrective Action: See an authorized Onan service representative.

5-5

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS (CONT.)

WARNING

injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

Some genset service procedures present hazards that can result in severe personal

FAULTY TEMPERATURE SENDER—CODE NO. 24

(Controller sensed open sender)

Corrective Action: See an authorized Onan service representative.

LOSS OF AC VOLTAGE SENSE—CODE NO. 27

(The genset Controller lost VAC sensing during normal voltage regulation when

the field was functioning normally and frequency was at least 40 Hz)

Corrective Action: See an authorized Onan service representative.

HIGH BATTERY VOLTAGE—CODE NO. 29

(During startup the genset Controller sensed that battery system voltage was greater than

19.2 volts if 12 VDC system or 32.2 volts if 24 volt system)

Corrective Action:

1. Check battery bank connections and reconnect if necessary for 12 volts or 24 volts, depending on
genset model.

2. Select a lower battery booster charge rate (external charging system).

STARTING FAULT—CODE NO. 32

(The genset Controller could not detect cranking speed [quadrature zero crossings] for 3 seconds)

Corrective Action:

1. De-energize the PTO clutch, if so equipped.

2. Have the propulsion engines running while trying to start the genset. Their charging alternators
may be able to maintain a high enough battery terminal voltage to start the genset.

3. Service as necessary by cleaning and tightening battery connections, recharging or replacing the
battery or replacing damaged battery cables (p. 4-2).

4. Change the engine oil to oil of the proper viscosity for the ambient temperature. High oil viscosity
can slow down cranking speed.

CONTROL CARD FAILURE−EE—CODE NO. 35

(During startup the genset Controller detected a EE memory error)

Corrective Action: See an authorized Onan service representative.

5-6

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS (CONT.)

WARNING

injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

Some genset service procedures present hazards that can result in severe personal

UNKNOWN SHUTDOWN—CODE NO. 36

(The genset Controller declared this fault because engine speed fell below 1000 RPM for 0.5 seconds,

though not by genset or engine control action)

Corrective Action:

1. Check for mechanical damage and service as necessary.

2. Push the genset line circuit breaker OFF and disconnect the PTO, if so equipped. If the genset
now runs, reduce the number of electrical and mechanical (PTO) loads.

3. Check fuel level and refill as necessary. (Note: The genset fuel pickups are probably higher than the
propulsion engine fuel pickups.)

4. Prime the engine fuel system for at least 30 seconds (p. 3-3).

5. Check all fuel fittings for fuel and air leaks and tighten as necessary.

6. Replace fuel filters (p. 4-6).

7. Remove combustion air or exhaust system blockages.

INVALID GENSET CONFIGURATION—CODE NO. 37

(The genset Controller is not configured properly for the genset )

Corrective Action: See an authorized Onan service representative.

FIELD OVERLOAD—CODE NO. 38

(High field voltage induced by high rotor temperature or low power factor loads)

Corrective Action:

1. Remove blockages to generator air flow at the front inlet air grill.

2. Reduce the number of appliances running at the same time, especially those with high motor starting
loads, such as air conditioners.

3. Have air conditioners and other appliances checked for proper operation. (A locked compressor
rotor can cause very low power factor.)

CONTROL CARD FAILURE−RAM—CODE NO. 43

(During startup the genset Controller detected a RAM memory error)

Corrective Action: See an authorized Onan service representative.

SPEED SENSE LOST—CODE NO. 45

(After start disconnect the genset Controller lost speed sense

[quadrature zero crossings] for 0.25 seconds)

Corrective Action: See an authorized Onan service representative.

5-7

TABLE 5-1. TROUBLESHOOTING GENSET FAULTS (CONT.)

WARNING

Some genset service procedures present hazards that can result in severe personal
injury or death. Only trained and experienced service personnel with knowledge of fuels, electricity,
and machinery hazards should perform genset service. See Safety Precautions.

Accidental or remote starting can cause severe personal injury or death. Before removing a panel or
access door, disconnect the negative (−) cable from the battery to prevent the engine from starting.

OVERPRIME—CODE NO. 57

(A local or remote control switch was held in the Prime position for more than 5 minutes)

Corrective Action: Check for and remove any object that may be holding any control switch (local or
remote) in the prime position.

HIGH EXHAUST TEMPERATURE—CODE NO. 58

(Exhaust temperature exceeded design limits due to lack of water delivered to the exhaust/water mixer)

Corrective Action:

1. Check for and clean a blocked sea water strainer. If above the water line, fill the strainer with water
to assist priming.

2. Inspect the siphon break (if provided) for proper operation.

3. Check for a worn raw water impeller and replace as necessary (p. 4-12).

4. Clean the heat exchanger (p. 4-8).

LOW COOLANT LEVEL—CODE NO. 59

(The engine coolant level fell below the optional coolant level sensor)

Corrective Action: Add coolant as necessary and repair leaks.

EXTERNAL SHUTDOWN—CODE NO. 61

(Genset was shut down by a fire suppression system or other external control)

Corrective Action: Make all necessary repairs to the genset and connected equipment and reset the
external control which shut down the genset.

5-8

6. Specifications

MDKBK MDKBL MDKBM MDKBN

ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.

FUEL CONSUMPTION:

60 Hz: Full Load

50 Hz: Full Load

ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing

Model D1105 D1105 V1305 V1505

Number of Cylinders 3 3 4 4

Displacement 68.58 in3 (1124 cm3) 68.58 in3 (1124 cm3) 81.47 in3 (1335 cm3) 91.44 in3 (1499 cm3)

Bore 3.07 in (78 mm) 3.07 in (78 mm) 2.99 in (76 mm) 3.07 in (78 mm)

Stroke 3.09 in (78.4 mm) 3.09 in (78.4 mm) 2.90 in (73.6 mm) 3.09 in (78.4 mm)

Compression Ratio 22:1 22:1 22:1 22:1

Firing Order (Clockwise Rotation) 1-2-3 1-2-3 1-2-4-3 1-2-4-3

Fuel Injection Timing 16.5° BTDC 16.5° BTDC 16.5° BTDC 16.5° BTDC

Valve Lash (cold)

Lube Oil Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 4.5 quart (4.3 liter) 4.5 quart (4.3 liter)

Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPT

Coolant Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 5.3 quart (5.0 liter) 5.3 quart (5.0 liter)

Coolant Flow Rate: 60 Hz

Raw Water Flow Rate: 60 Hz

Combustion Air Flow: 60 Hz

Heat Rejection to Ambient: 60 Hz

Maximum Angularity 10° Continuous, 22.5° Intermittent

Recommended Fuel No. 2-D Diesel Fuel: Spec EN 590 or ASTM D975

Recommended Coolant

CONNECTIONS:

Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)

Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female

Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female

Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)

Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose

Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose

Dry Exhaust Outlet 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT

Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg

KEEL COOLING:

Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose

Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)

Heat Rejection to Coolant: 60 Hz

Thermostat Opening Temperature 185° F (85° C) 185° F (85° C) 185° F (85° C) 185° F (85° C)

BATTERIES:

Nominal Battery Voltage 12 volts (24 volts optional) 12 volts (24 volts optional) 12 volts (24 volts optional) 12 volts (24 volts optional)

Min CCA Rating − SAE @ 32° F (0° C) 360 amps 360 amps 500 amps 500 amps

Battery Charging @ 12/24 VDC 5/10 amps 5/10 amps 5/10 amps 5/10 amps

SIZE, WEIGHT, NOISE:

Without Enclosure

Dry Weight
Dimensions: L x W x H

With Enclosure

Noise
Dry Weight
Dimensions: L x W x H

Half Load

Half Load

50 Hz

50 Hz

50 Hz

50 Hz

50 Hz

0.8 gph (3.0 liter/hr)

0.5 gph (1.9 liter/hr)

0.7 gph (2.7 liter/hr)

0.4 gph (1.5 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

5.0 gpm (18.9 liter/min)

4.2 gpm (15.9 liter/min)

6.0 gpm (22.7 liter/min)

5.0 gpm (18.9 liter/min)

30 cfm (0.85 m3/min)
25 cfm (0.71 m

200 Btu/min (50 kcal/min)
179 Btu/min (45 kcal/min)

950 Btu/min (239 kcal/min)
780 Btu/min (197 kcal/min)

525 lbs (238 kg)

32.4 x 18.9 x 22.1 in

(479.1 x 822.6 x 560.9 mm)

3

/min)

− 66/65 dB(A) @ 60/50HZ

0.8 gph (3.0 liter/hr)

0.5 gph (1.9 liter/hr)

0.7 gph (2.7 liter/hr)

0.4 gph (1.5 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

5.0 gpm (18.9 liter/min)

4.2 gpm (15.9 liter/min)

6.0 gpm (22.7 liter/min)

5.0 gpm (18.9 liter/min)

30 cfm (0.85 m3/min)
25 cfm (0.71 m

200 Btu/min (50 kcal/min)
179 Btu/min (45 kcal/min)

Ethylene Glycol: Spec ASTM D5345 for 50/50 Prediluted Coolant or

ASTM D4985 for Concentrated Coolant with 40% to 60% quality water

950 Btu/min (239 kcal/min)
780 Btu/min (197 kcal/min)

555 lbs (252 kg)

35.9 x 22.3 x 23.0 in

(911 x 566 x 585 mm)

600 lbs (272 kg)

35.9 x 22.3 x 23.4 in

(911 x 566 x 593 mm)

3

/min)

1.0 gph (3.8 liter/hr)

0.6 gph (2.3 liter/hr)

0.8 gph (3.0 liter/hr)

0.5 gph (1.9 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

5.0 gpm (18.9 liter/min)

4.2 gpm (15.9 liter/min)

6.0 gpm (22.7 liter/min)

5.0 gpm (18.9 liter/min)

36 cfm (1.02 m3/min)

30 cfm (0.85 m

230 Btu/min (58 kcal/min)
190 Btu/min (48 kcal/min)

1220 Btu/min (307 kcal/min)

980 Btu/min (247 kcal/min)

640 lbs (290 kg)

40.7 x 22.3 x 23.0 in

(1033 x 566 x 585 mm)

66/65 dB(A) @ 60/50HZ

695 lbs (315 kg)

40.7 x 22.3 x 23.4 in

(1033 x 566 x 593 mm)

3

/min))

1420 Btu/min (358 kcal/min)
1160 Btu/min (292 kcal/min)

1.2 gph (4.5 liter/hr)

0.7 gph (2.7 liter/hr)

0.9 gph (3.4 liter/hr)

0.5 gph (1.9 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

5.0 gpm (18.9liter/min)

4.2 gpm (15.9 liter/min)

6.0 gpm (22.7 liter/min)

5.0 gpm (18.9 liter/min)

41 cfm (1.16 m3/min)
34 cfm (0.96 m

280 Btu/min (71 kcal/min)
210 Btu/min (53 kcal/min)

640 lbs (290 kg)

40.7 x 22.3 x 23.0 in

(1033 x 566 x 585 mm)

66/65 dB(A) @ 60/50HZ

695 lbs (315 kg)

40.7 x 22.3 x 23.4 in

(1033 x 566 x 593 mm)

3

/min)

6-1

MDKBP MDKBR MDKBS

ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.

FUEL CONSUMPTION:

60 Hz: Full Load

50 Hz: Full Load

ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing

Model V1903B V2203B V2803B

Number of Cylinders 4 4 5

Displacement 113.37 in3 (1857 cm3) 134.07 in3 (2197cm3) 167.57 in3 (2748 cm3)

Bore 3.15 in (80 mm) 3.43 in (87 mm) 3.43 in (87 mm)

Stroke 3.64 in (92.4 mm) 3.64 in (92.4 mm) 3.64 in (92.4 mm)

Compression Ratio 23:1 23:1 23:1

Firing Order (Clockwise Rotation) 1-3-4-2 1-3-4-2 1-3-5-4-2

Fuel Injection Timing 14.5° BTDC 16° BTDC 16° BTDC

Valve Lash (cold)

Lube Oil Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 12.7 quart (12 liter)

Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT

Coolant Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 8 quart (7.6 liter)

Coolant Flow Rate: 60 Hz

Raw Water Flow Rate: 60 Hz

Combustion Air Flow: 60 Hz

Heat Rejection to Ambient: 60 Hz

Maximum Angularity 10° Continuous, 22.5° Intermittent

Recommended Fuel No. 2-D Diesel Fuel: Spec EN 590 or ASTM D975

Recommended Coolant

CONNECTIONS:

Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)

Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female

Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female

Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)

Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose

Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose

Dry Exhaust Outlet 1-1/2 NPT 1-1/2 NPT 1-1/2 NPT

Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg

KEEL COOLING:

Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose

Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)

Heat Rejection to Coolant: 60 Hz

Thermostat Opening Temperature 185° F (85° C) 185° F (85° C) 185° F (85° C)

BATTERIES:

Nominal Battery Voltage 12 volts (24 volts optional) 12 volts (24 volts optional) 12 volts (24 volts optional)

Min CCA Rating − SAE @ 32° F (0° C) 500 amps 625 amps 625 amps

Battery Charging @ 12/24 VDC 40/20 amps 40/20 amps 40/20 amps

SIZE, WEIGHT, NOISE:

Without Enclosure

Dry Weight
Dimensions: L x W x H

With Enclosure

Noise
Dry Weight
Dimensions: L x W x H

Half Load

Half Load

50 Hz

50 Hz

50 Hz

50 Hz

50 Hz

1.3 gph (4.9 liter/hr)

0.8 gph (3.0 liter/hr)

1.1 gph (4.2 liter/hr)

0.7 gph (2.7 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

14.0 gpm (53.0 liter/min)

10.0 gpm (37.9 liter/min)

9.0 gpm (34.1 liter/min)

7.0 gpm (26.5 liter/min)

52 cfm (1.45 m3/min)
42 cfm (1.21 m

350 Btu/min (88 kcal/min)
285 Btu/min (72 kcal/min)

1590 Btu/min (402 kcal/min)
1500 Btu/min (379 kcal/min)

830 lbs (377 kg)

44.4 x 23.7 x 26.1 in

(1127 x 602 x 663 mm)

67/64 dB(A) @ 60/50 HZ

890 lbs (404 kg)

44.4 x 23.7 x 27.5 in

(1127 x 602 x 698 mm)

3

/min)

Ethylene Glycol: Spec ASTM D5345 for 50/50 Prediluted Coolant or

ASTM D4985 for Concentrated Coolant with 40% to 60% quality water

1.9 gph (7.2 liter/hr)

1.1 gph (4.2 liter/hr)

1.6 gph (6.1 liter/hr)

0.9 gph (3.4 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

14.0 gpm (53.0 liter/min)

10.0 gpm (37.9 liter/min))

9.0 gpm (34.1 liter/min)

7.0 gpm (26.5 liter/min)

60 cfm (1.72 m3/min)

50 cfm (1.43 m

420 Btu/min (106 kcal/min)

350 Btu/min (88 kcal/min)

1980 Btu/min (500 kcal/min)
1670 Btu/min (422 kcal/min)

870 lbs (375 kg)

44.4 x 23.7 x 26.1 in

(1127 x 602 x 663 mm)

67/64 dB(A) @ 60/50 HZ

930 lbs (422 kg)

44.4 x 23.7 x 27.5 in

(1127 x 602 x 698 mm)

3

/min))

2.5 gph (9.5 liter/hr)

1.5 gph (5.7 liter/hr)

2.1 gph (8.0 liter/hr)

1.3 gph (4.9 liter/hr)

0.0071 − 0.0087 in
(0.18 − 0.22 mm)

14.0 gpm (53.0 liter/min)

10.0 gpm (37.9 liter/min)

9.0 gpm (34.1 liter/min)

7.0 gpm (26.5 liter/min)

75 cfm (2.12 m3/min)
63 cfm (1.78 m

530 Btu/min (134 kcal/min)
450 Btu/min (114 kcal/min)

2490 Btu/min (629 kcal/min)
2090 Btu/min (528 kcal/min)

1090 lbs (494 kg)

53.5 x 23.7 x 28.8 in

(1358 x 602 x 732 mm)

68/67 dB(A) @ 60/50 HZ

1175 lbs (533 kg)

53.5 x 23.7 x 30.0 in

(1358 x 602 x 763 mm)

3

/min)

6-2

MDKBT MDKBU

ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.

FUEL CONSUMPTION:

60 Hz: Full Load

50 Hz: Full Load

ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing

Model V3300-E2B V3300-E2B

Number of Cylinders 4 4

Displacement 202.48 in3 (3318 cm3) 202.48 in3 (3318 cm3)

Bore 3.86 in (98 mm) 3.86 in (98 mm)

Stroke 4.33 in (110 mm) 4.33 in (110 mm)

Compression Ratio 22.5:1 22.5:1

Firing Order (Clockwise Rotation) 1-3-4-2 1-3-4-2

Fuel Injection Timing 12° BTDC 12° BTDC

Valve Lash (cold)

Lube Oil Capacity 11 quart (10.4 liter) 11 quart (10.4 liter)

Lube Oil Drain Connection 3/8 NPT 3/8 NPT

Coolant Capacity 14.5 quart (13.7 liter) 14.5 quart (13.7 liter)

Coolant Flow Rate: 60 Hz

Raw Water Flow Rate: 60 Hz

Combustion Air Flow: 60 Hz

Heat Rejection to Ambient: 60 Hz

Maximum Angularity 10° Continuous, 22.5° Intermittent

Recommended Fuel No. 2-D Diesel Fuel: Spec EN 590 or ASTM D975

Recommended Coolant

CONNECTIONS:

Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m)

Fuel Supply 1/4 NPT female 1/4 NPT female

Fuel Return 1/4 NPT female 1/4 NPT female

Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m)

Raw Water Inlet 1.25 in (31.7 mm) ID Hose 1.25 in (31.7 mm) ID Hose

Wet Exhaust Outlet 3 in (76.2 mm) ID Hose 3 in (76.2 mm) ID Hose

Dry Exhaust Outlet 2 in NPT 2 in NPT

Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg

KEEL COOLING:

Coolant Inlet & Outlet 1.25 in (31.7 mm) ID Hose 1.25 in (31.7 mm) ID Hose

Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa)

Heat Rejection to Coolant: 60 Hz

Thermostat Opening Temperature 170° F (76.5° C) 170° F (76.5° C)

BATTERIES:

Nominal Battery Voltage 12 volts (24 volts optional) 12 volts (24 volts optional)

Min CCA Rating − SAE @ 32° F (0° C) 625 amps 625 amps

Net Battery Charging (Negative Ground)

Net Battery Charging (Isolated Ground)

SIZE, WEIGHT, NOISE:

Without Sound Shield

Dry Weight
Dimensions: L x W x H

With Sound Shield

Noise
Dry Weight
Dimensions: L x W x H

Half Load

Half Load

50 Hz

50 Hz

50 Hz

50 Hz

50 Hz

53.5 x 24.5 x 28.8 in (1358 x 622 x 731 mm)

53.5 x 24.5 x 30.0 in (1358 x 622 x 761 mm)

2.5 gph (9.5 liter/hr)

1.5 gph (5.7 liter/hr)

2.1 gph (8.0 liter/hr)

1.5 gph (5.6 liter/hr)

0.009 − 0.010 in

(0.23 − 0.27 mm)

14.0 gpm (53.0 liter/min)

11.5 gpm (43.5 liter/min)

15.6 gpm (59.1 liter/min)

13.0 gpm (49.2 liter/min)

91.7 cfm (2.6 m3/min)

76.5 cfm (2.2 m

532 Btu/min (134 kcal/min)
441 Btu/min (111 kcal/min)

Ethylene Glycol: Spec ASTM D5345 for 50/50 Prediluted Coolant or

ASTM D4985 for Concentrated Coolant with 40% to 60% quality water

2200 Btu/min (555 kcal/min)
1870 Btu/min (470 kcal/min)

12 volts: 30.0/22.0 amps (60/50 Hz)
24 volts: 22.5/20.5 amps (60/50 Hz)

12 volts: 43.0/40.0 amps (60/50 Hz)
24 volts: 30.5/28.5 amps (60/50 Hz)

1245 lbs (565 kg)

68/67 dB(A) @ 60/50 HZ

1325 lbs (601 kg)

3

/min)

3.0 gph (11.2 liter/hr)

1.5 gph (5.6 liter/hr)

2.4 gph (9.1 liter/hr)

1.5 gph (5.7 liter/hr)

0.009 − 0.010 in

(0.23 − 0.27 mm)

14.0 gpm (53.0 liter/min)

11.5 gpm (43.5 liter/min)

15.6 gpm (59.1 liter/min)

13.0 gpm (49.2 liter/min)

91.7 cfm (2.6 m3/min)

76.5 cfm (2.2 m

629 Btu/min (159 kcal/min)
515 Btu/min (130 kcal/min)

2600 Btu/min (655 kcal/min)
2200 Btu/min (555 kcal/min)

12 volts: 30.0/22.0 amps (60/50 Hz)

24 volts: 22.5/20.5 amps (60/50 Hz

12 volts: 43.0/40.0 amps (60/50 Hz)
24 volts: 30.5/28.5 amps (60/50 Hz)

53.5 x 24.5 x 28.8 in (1358 x 622 x 731 mm)

53.5 x 24.5 x 30.0 in (1358 x 622 x 761 mm)

1300 lbs (590 kg)

68/67 dB(A) @ 60/50 HZ

1380 lbs (626 kg)

3

/min)

6-3

This side is intentionally blank

7. Maintenance Record

Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Section 4).

HOUR

DATE

METER

READING

MAINTENANCE OR SERVICE PERFORMED

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

7-1

This side is intentionally blank