Operator’s Manual

MDKBK MDKBL MDKBM MDKBN

MDKBP MDKBR MDKBS
MDKBT MDKBU
981-0175C
01-07

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 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.

Redistribution or publication of this document,

by any means, is strictly prohibited.
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

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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

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SAFETY PRECAUTIONS

Thoroughly read the OPERATOR’S MANUAL • The genset must not be connected to shore
before operating the genset. Safe operation and power or to any other source of electrical pow-
top performance can only be obtained when er. Back-feed to shore power can cause elec-
equipment is operated and maintained proper- tric shock resulting in severe personal injury or
ly. death and damage to equipment. An approved
switching device must be used to prevent inter-
The following symbols in this manual alert you to connections.
potential hazards to the operator, service person
and equipment. • Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
DANGER alerts you to an immediate hazard ing and shoes are dry, stand on a dry wooden
that will result in severe personal injury or platform or rubber insulating mat and use tools
death. with insulated handles.

WARNING alerts you to a hazard or unsafe

DIESEL FUEL IS COMBUSTIBLE
practice that can result in severe personal inju-
ry or death. • Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
CAUTION alerts you to a hazard or unsafe
sharing ventilation with fuel tanks or equip-
practice that can result in personal injury or ment. Keep flames, sparks, pilot lights, arc-
equipment damage. producing equipment and all other sources of
ignition well away.
Electricity, fuel, exhaust, moving parts and batter-
ies present hazards which can result in severe per- • Fuel lines must be secured, free of leaks and
sonal injury or death. separated or shielded from electrical wiring.

ENGINE EXHAUST IS DEADLY

MOVING PARTS CAN CAUSE SEVERE
• Never sleep in the boat while the genset is run-
PERSONAL INJURY OR DEATH
ning unless the boat is equipped with properly
working carbon monoxide detectors. • Do not wear loose clothing or jewelry near
• The exhaust system must be installed in accor- moving parts such as PTO shafts, fans, belts
dance with the genset Installation Manual and and pulleys.
be free of leaks.
• Keep hands away from moving parts.
• Make sure the bilge is adequately ventilated
with a power exhauster. • Keep guards in place over fans, belts, pulleys,
• Inspect for exhaust leaks every startup and af- and other moving parts.
ter every eight hours of operation.
• For more information about carbon monoxide BATTERY GAS IS EXPLOSIVE
see American Boat and Yacht Council (ABYC)
publication TH-22—Educational Information • Wear safety glasses.
About Carbon Monoxide.
• Do not smoke.
GENERATOR VOLTAGE IS DEADLY
• To reduce arcing when disconnecting or recon-
• Generator electrical output connections must necting battery cables, always disconnect the
be made by a trained and experienced electri- negative (−) battery cable first and reconnect
cian in accordance with applicable codes. it last.

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 FLAMMABLE VAPOR CAN CAUSE A • Keep the genset, drip pan and compartment
DIESEL ENGINE TO OVERSPEED clean. Oily rags can catch fire. Gear stowed in
the compartment can restrict cooling.
Flammable vapor can cause a diesel engine to • Make sure all fasteners are secure and proper-
overspeed and become difficult to stop, resulting in ly torqued.
possible fire, explosion, severe personal injury and • Do not work on the genset when mentally or
death. Do not operate a diesel-powered genset physically fatigued or after having consumed
where a flammable vapor environment can be alcohol or drugs.
created by fuel spill, leak, etc. The owners and
operators of the genset are solely responsible for • You must be trained and experienced to make
operating the genset safely. adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
vere personal injury or death.
GENERAL PRECAUTIONS • Used engine oil has been identified by some
• Keep children away from the genset. U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
• Do not use evaporative starting fluids. They inhale, or contact used oil or its vapors.
are highly explosive. • Ethylene glycol, used as engine coolant, is tox-
• Do not step on the genset when entering or ic to humans and animals. Clean up spills and
leaving the generator room. Parts can bend or dispose of used engine coolant in accordance
break leading to electrical shorts or to fuel, with local environmental regulations.
coolant or exhaust leaks. • Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus-
• To prevent accidental or remote starting while tible materials such as wood and cloth; Class B
working on the genset, disconnect the nega- fires, combustible and flammable liquid fuels
tive (−) battery cable at the battery. and gaseous fuels; Class C fires, live electrical
• Let the engine cool down before removing the equipment. (ref. NFPA No. 10)
coolant pressure cap or opening the coolant • Genset installation and operation must comply
drain. Hot coolant under pressure can spray with all applicable local, state and federal
and cause severe burns. codes and regulations.

POST THESE SAFETY PRECAUTIONS IN POTENTIAL

HAZARD AREAS OF THE BOAT
M-10

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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 This genset is not a life support sys-

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

Operation, Periodic Maintenance and Trouble-

shooting provide the instructions necessary for op-
erating the genset and maintaining it at top perfor-
mance. 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® replace-
ment parts are recommended for best results.

MODEL IDENTIFICATION
MODEL NUMBER: ______________________
Be ready to provide the genset model and serial
numbers on the nameplate when contacting Onan SERIAL NUMBER: ______________________
for parts, service and product information. Fig-
ure 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 FIGURE 1-1. TYPICAL NAMEPLATE
model number is the specification letter, which is im-
portant for obtaining the right parts.) Record the
genset model and serial numbers on the lines desig-
nated in the figure so that they are easy to find when
you need them.

WARNING Improper service or replacement of

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

1-1 Redistribution or publication of this document,

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 HOW TO OBTAIN SERVICE EMISSIONS LABEL
For genset parts, service, and product information The label that states compliance with applicable en-
(such as the Service Manual), contact the nearest gine emissions regulations is located on the engine
authorized Cummins/Onan distributor. You may go as circled in Figure 1-2. Refer also to the FEDERAL
to Internet site www.onan.com for information for EMISSION DESIGN AND DEFECT LIMITED WAR-
contacting our distributors worldwide. RANTY FOR C. I. ENGINES (DIESELS) that was
shipped in the same package as the Operator’s
In North America Manual.
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. Typi-
cally, 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 (Cen-
tral Standard Time), Monday through Friday, or fax
1−763−528−7229.

Information To Have Available

FIGURE 1-2. TYPICAL EMISSIONS LABEL
1. Model Number, including Spec Letter, and Seri-
LOCATIONS
al Number (Figure 1-1).
2. Date of purchase.
3. Nature of problem (Section 5. Troubleshoot-
ing).

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2. Control Panel
REMOTE CONTROL AND MONITORING • Push and Hold STOP (Prime) to prime the fuel
system (amber lamp comes on in 2 seconds to
Remote e-Series Digital Displays and indicate priming).
Control Switches
Status Lamps: The control switch has two status
The boat may be equipped with several remote gen- lamps. The amber status lamp comes on during
set control stations having either an e-Series Digital priming, blinks rapidly during cranking and goes out
Display or control switch. when the engine is up to speed. If the genset shuts
down abnormally, this lamp will slowly blink a nu-
Boat Monitoring System merical code to indicate the cause of shutdown. See
Troubleshooting (Section 5). The green status lamp
The boat may also be equipped to monitor genset
operation on an integrated monitoring system using comes on to indicate that the genset is running.
an SAE J1939 or SmartCraft™ network protocol.
Emergency Stop Switch: In an emergency push
LOCAL CONTROL PANEL the switch to OFF. Push it to ON after all necessary
repairs to the genset and connected equipment
Refer to Figure 2-1. have been made.

Control Switch Panel (Standard) DC Circuit Breaker: This circuit breaker protects
the DC control circuits of the genset from short cir-
Control Switch: This switch is used to start and
cuits. Reset after all necessary repairs have been
stop the genset and prime fuel.
made to the genset.
• Push and Hold START to preheat, crank and
start the genset. The green lamp comes on Hour Meter: The hour meter records genset operat-
when the genset is running. (Preheat is the pe- ing time in hours. It cannot be reset.
riod of time prior to engine cranking when the
glow plugs preheat the combustion chambers. e-Series Digital Display Panel (Optional)
The time is automatically varied by the genset
controller on the basis of engine temperature.) The control panel may have an e-Series Digital Dis-
• Push and Release STOP (Prime) to stop the play instead of a control switch. See Page 2-3 for
genset. details.

SmartCraft is a trademark of the Brunswick Corporation.

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 OPTIONAL DIGITAL
DISPLAY PANEL

DIGITAL DISPLAY
DC CIRCUIT
BREAKER
EMERGENCY
STOP SWITCH

STANDARD CONTROL
SWITCH PANEL

HOUR CONTROL SWITCH

METER WITH STATUS LAMPS
EMERGENCY
DC CIRCUIT STOP SWITCH
BREAKER

FIGURE 2-1. GENSET CONTROL PANEL

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 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 sta-
tion. 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 FIGURE 2-2. DIGITAL DISPLAY
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 START-
ING THE GENSET (p. 3-3).
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 GEN-
SET (p. 3-3).
Priming the Fuel System: Push and Hold STOP.
The GENSET status lamp will blink. The status dis-
played on the LCD will change to Priming in 2 sec-
onds (Figure 2-3). See PRIMING THE FUEL SYS-
TEM (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).

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Genset Status
Genset status is displayed on 3 screen pages (Fig-
ure 2-3). GEN STATUS PG1 appears when the Dis-
play is turned on. Press the double arrows [ ] to
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
Fig. 2-7

To
Fig. 2-5

To
Fig. 2-8

FIGURE 2-3. TYPICAL GENSET STATUS SCREENS

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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. TROUBLE-
SHOOTING GENSET FAULTS to diagnose and
correct the problem.

The e-Series Digital Display will display the fault in-

definitely. Touch any button to clear the fault. The
FIGURE 2-4. TYPICAL FAULT SCREEN
display will turn off in 5 minutes after the fault has
been cleared.

Press [ BACK] to go back to the GEN STATUS

screen.

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Fault History From FAULT, Fig. 2-3
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 oc-
curred. Press the double arrows [ ] to toggle be-
tween 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
The PRE-ALARM status lamp will come on when
OR
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.

FIGURE 2-5. FAULT HISTORY

From FAULT, Fig. 2-3

OR

FIGURE 2-6. ENGINE PRE-ALARMS

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Brightness and Contrast
From SCREEN, Fig. 2-3
To adjust the brightness and contrast of the LCD
screen and status lamps, go to the SCREEN AD-
JUST 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.)

Press [ BACK] to save the settings and go back to

GEN STATUS.
FIGURE 2-7. SCREEN BRIGHTNESS & CONTRAST
Display Setup
From SETUP, Fig. 2-3
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 [ ] to toggle between
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).

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 ad-
just AC output voltage, if necessary, before calibrat-
ing 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 [ BACK] to get back to GEN STA-

TUS. FIGURE 2-8. SETUP, GENSET & DISPLAY INFO

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This side is intentionally blank

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3. Operation

FUEL

WARNING Diesel fuel is combustible and can

cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment 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 multi-
class ABC fire extinguisher handy.

High quality Grade 2-D diesel fuel is necessary for FIGURE 3-1. OIL VISCOSITY GRADE VS. AMBIENT
good performance and long engine life. Diesel fuels TEMPERATURE
specified by EN 590 or ASTM D975 are recom-
mended. Use Grade 1-D diesel fuel if the fuel tank is
exposed to temperatures below 40° F (5° C). ENGINE COOLANT

The Cetane number should not be less than 45 and Use the best quality ethylene glycol antifreeze solu-
sulfur content not more than 0.5 percent (by weight). tion available. It should be a fully formulated with
Where fuel is exposed to cold ambient tempera- rust inhibitors and coolant stabilizers. A 50/50 mix-
tures, use fuel that has a cloud point (temperature at ture of water and ethylene glycol is recommended to
which wax crystals begin to form) at least 10° F provide protection from freezing down to -34° F
(6° C) degrees below the lowest expected fuel tem- (-37° C).
perature.
Use fresh water that is low in minerals and corrosive
Fuel lubricity should pass a minimum load level of chemicals for the coolant mixture. Distilled water is
3100 grams as measured by ASTM D6078 or maxi- best.
mum scar diameter of 0.45 mm as measured by
ASTM D6079 or ISO 12156-1. See Specifications (Section 6) regarding coolant
capacity.
Note:Ultra Low Sulfur Diesel (ULSD) fuel that meets
the ASTM D975 standard for lubricity is suitable for WARNING Ethylene Glycol antifreeze is con-
use with this engine. The 1 to 2 percent less energy sidered toxic. Dispose of it according to local
content of the fuel can have a slight effect on maxi- regulations for hazardous substances.
mum engine power.
BATTERIES
Note:B5 Bio-Diesel fuel that meets industry specifi-
cations and quality is suitable for use with this en- Reliable genset starting and starter service life de-
gine. pend upon adequate battery system capacity and
maintenance. See MAINTAINING THE BATTERY
ENGINE OIL AND BATTERY CONNECTIONS (p. 4-2) and
Specifications (Section 6).
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 ex-
pected until the next scheduled oil change. Multi-
grade oils such as SAE 15W-40 are recommended
for year-round use.

3-1 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 PRE-START CHECKS STARTING THE GENSET
The genset can be started and stopped from the
WARNING EXHAUST GAS is deadly. All en- genset control panel or remote control panel.
gine exhaust contains carbon monoxide; an 1. Push and Hold START on the e-Series Digital
odorless, colorless, poisonous gas that can Display or control switch until the genset starts.
cause unconsciousness and death. Symptoms The genset status lamp blinks when the engine
of carbon monoxide poisoning include: is cranking and comes on and stays on when
the genset starts and runs. The status dis-
• Dizziness • Headache played on the e-Series Digital Display changes
• Nausea • Weakness and Sleepiness from Starting to Running (Figure 2-3).
• Vomiting • Inability to Think Coherently 2. For longer engine life, let the engine warm up
for two minutes before connecting air condi-
GET EVERYONE OUT INTO FRESH AIR IMMEDI- tioners and other large electrical loads or en-
ATELY IF ANYONE EXPERIENCES ANY OF gaging the PTO (if so equipped).
THESE SYMPTOMS. Seek medical attention if 3. Check for water, coolant, fuel and exhaust
symptoms persist. Never sleep in the boat when leaks. Stop the genset immediately if there is a
the genset is running, unless the cabin has a leak. Repair fuel leaks immediately.
working carbon monoxide detector.
4. Monitor generator set status using the e-Series
Look over the entire exhaust system and listen Digital Display (p. 2-4), if so equipped. Perform
for leaks every time you start up the genset and maintenance or service as necessary if the Dis-
after every eight hours of operation. Shut down play indicates a Pre-Alarm condition (p. 2-3).
the genset immediately if there is a leak. Do not 5. If the genset fails to start, cranking will dis-
run the genset until the leak has been repaired. continue in 20 to 60 seconds, depending on en-
The exhaust system must be installed in accor- gine temperature. The e-Series Digital Display
dance with the genset Installation Manual. 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
Before the first start of the day and after every eight tries.
hours of operation, inspect the genset as instructed
CAUTION Do not continue cranking and
under GENERAL INSPECTION (p. 4-2). Keep a log
risk burning out the starter or flooding the
of maintenance and the hours run and perform any
engine (exhaust flow during cranking is too
maintenance that may be due. See Returning the
low to expel water from a wet exhaust sys-
Genset to Service (p. 3-6) if the boat has been in
tem). Find out why the genset does not start
storage. Before each start:
and make necessary repairs.
1. Make sure all CO detectors on board are work- 6. If the genset shuts down, the e-Series Digital
ing properly. Display and/or control switch status lamp will
indicate the numeric fault code. See Trouble-
2. Check for swimmers that might be exposed to shooting (Section 5).
the engine exhaust.
STOPPING THE GENSET
3. Disconnect all electrical loads and disengage Disconnect all electrical loads and disengage the
the PTO (if so equipped). 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 con-
PRIMING THE FUEL SYSTEM
trol switch. The genset status lamps will go out.
EMERGENCY STOP
The fuel system should be primed after replacing
the fuel filter or running the genset out of fuel. To Push the EMERGENCY STOP SWITCH to OFF
prime the fuel system, Push and Hold STOP on the (p. 2-1). After all necessary repairs have been
e-Series Digital Display or STOP (Prime) on the made, push the switch to ON so that the genset can
control switch for at least 30 seconds. be operated.

3-3 Redistribution or publication of this document,

by any means, is strictly prohibited.
 LOADING THE GENSET 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 automati-
How much equipment load can be powered de- cally disconnect all or most electrical loads when the
pends upon the genset power rating. The genset will PTO is engaged. It may be necessary to run fewer
shut down or its AC output circuit breakers will trip if electrical loads—or none at all—when the PTO
the sum of the loads exceeds genset power or cir- is engaged.
cuit breaker rating. The genset is rated at standard barometric pres-
sure, humidity and temperature (ref. ISO 3046). Ei-
ther low barometric pressure (high altitude) or high
To avoid overloading the genset and causing shut- ambient temperature will decrease engine power. It
downs, compare the sum of the loads of the ap- may be necessary to run fewer loads under such
pliances that are likely to be used at the same time conditions.
with the power rating of the genset. Use Table 3-1 or TABLE 3-1. TYPICAL APPLIANCE LOADS
the ratings on the appliances themselves to obtain Appliance Load (watts)
the individual appliance loads. If the appliance is Air Conditioner 1400-2000
marked in amps and volts only, multiply the amps Battery Charger Up to 3000
times the volts to obtain the appliance load (watts). DC Converter 300-700
It may be necessary to run fewer appliances at Refrigerator 600-1000
the same time—the sum of the loads must not Microwave Oven 1000-1500
be greater than genset rating. Electric Frying Pan or Wok 1000-1500
Electric Stove Element 350-1000
Electric Water Heater 1000-1500
The genset may shut down due to overload when a Electric Iron 500-1200
large motor or air conditioner is started or cycles off Electric Hair Dryer 800-1500
and then on again, even though the sum of the loads Coffee Percolator 550-750
is less than genset rating. The reason for this is that Television 200-600
a motor’s startup load is much larger than its running Radio 50-200
load. It may be necessary to run fewer loads Electric Drill 250-750
when large motors and air conditioners are cycl- Electric Broom 200-500
ing on and off. Electric Blanket 50-200

3-4 Redistribution or publication of this document,

by any means, is strictly prohibited.
 NO-LOAD OPERATION
Keep no-load operation to a minimum. During LINE CIRCUIT BREAKER HANDLES
no-load operation cylinder temperatures drop to the PULL FORWARD FOR ON
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 con-
nected. Note that the genset will continue to run af-
ter a line circuit breaker trips.
If a circuit breaker trips, disconnect or turn off as
many loads as possible and reset the circuit break-
er. If the circuit breaker trips right away, either the
electrical distribution system has a short or the cir-
cuit 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.
Electrical equipment must be used and maintained FIGURE 3-3. TYPICAL LINE CIRCUIT BREAKERS
properly and be properly grounded to cause the line
circuit breakers to trip when short circuits occur.
WARNING Short circuits in electrical equip-
ment can cause fire and electrical shock leading
to severe personal injury or death. Electrical
equipment and its grounding must be main-
tained 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 de-
vice to keep the genset and shore power from being
interconnected.
WARNING Interconnecting the genset and
shore power can lead to electrocution of utility
line workers, equipment damage and fire. Use
an approved switching device to prevent inter-
connections.

3-5 Redistribution or publication of this document,

by any means, is strictly prohibited.
 COLD TEMPERATURE OPERATION 4. Disconnect the battery cables (negative [−]
cable first) from the starting battery and store
Drain the heat exchanger (p. 4-8) and muffler be- the battery according to the battery manufac-
fore cold weather sets in if the genset is not being turer’s recommendations. See MAINTAINING
used. Freezing water can damage the muffler and THE BATTERY AND BATTERY CONNEC-
the raw water tubes in the heat exchanger. TIONS (p. 4-2).

CARE OF NEW OR RE-BUILT ENGINE 5. Check coolant level and add as necessary
(p. 4-7). Test the coolant mixture if freezing
Avoid no-load operation as much as possible during temperatures are possible and change if nec-
break-in. Change the oil and oil filter after the first 50 essary.
hours of operation (p. 4-3). WARNING Hot coolant is under pressure
and can cause severe burns when loosen-
EXERCISING THE GENSET ing the pressure cap. Let the engine cool
before loosening the pressure cap.
Exercise the genset at least 1 hour every month if
use is infrequent. Run the genset at 1/4 to 3/4 load. 6. Drain the heat exchanger and muffler if freezing
A single exercise period is better than several short- temperatures are expected.
er periods. Exercising a genset drives off moisture, 7. Disengage a PTO clutch if so equipped.
re-lubricates the engine, uses up fuel before it be-
comes stale and removes oxides from electrical 8. Clean and lightly oil parts that can rust.
contacts. The result is better starting, more reliable
Returning the Genset to Service
operation and longer engine life.
1. Check the oil tag on the genset and change the
STORING THE GENSET oil if the viscosity indicated is not appropriate for
the temperatures expected. See ENGINE OIL
Proper storage is essential for preserving top gen- RECOMMENDATIONS (p. 3-1).
set performance and reliability when the genset
cannot be exercised regularly and will be idle for 2. Reconnect the starting battery (negative [−]
more than 120 days. cable last). See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 4-2).
Storing the Genset 3. Replace the raw water pump impeller if it was
1. Turn off the genset line circuit breaker. installed more than a year ago (p. 4-12).

2. Change the engine oil and filter and attach a tag 4. Perform the maintenance required (p. 4-1),
indicating oil viscosity. See ENGINE OIL REC- conduct the pre-start checks and prime the fuel
OMMENDATIONS (p. 3-1). system.

3. Crank the engine several revolutions but do not 5. Start and run the genset.
let it start. This will fill the oil passages with the 6. Turn on the genset line circuit breaker when
new oil. ready to power loads.

3-6 Redistribution or publication of this document,

by any means, is strictly prohibited.
4. Periodic Maintenance

Periodic maintenance is essential for top perfor- To help you keep genset maintenance regular and
mance and long genset life. Use Table 4-1 as a provide a basis for warranty claims, record mainte-
guide for normal periodic maintenance. nance performed in Maintenance Record (Sec-
tion 7).
Maintenance, replacement or repair of emission
control devices and systems may be performed by WARNING Accidental or remote starting can
any engine repair establishment or individual. How- cause severe personal injury or death. Discon-
ever, warranty work must be completed by an au- nect the negative (−) cable at the battery to pre-
thorized Onan service representative. vent starting while working on the genset.

TABLE 4-1. PERIODIC MAINTENANCE SCHEDULE

MAINTENANCE FREQUENCY
Every
Every Every Every Every
MAINTENANCE OPERATION After Every
Month/ Year/ Year/ Year/
Every Every 5
First Day / 800 2 Years/ Page
100 200 350 500
50 Hrs 8 Hrs Hrs Years 2000
Hrs Hrs Hrs Hrs
Hrs

General Inspection1 • 4-2

Check Engine Oil Level • 4-3

Drain Water from Fuel Filter • 4-6

Inspect Battery and Battery Connec-

• 4-2
tions2
Check V-Belt Tension3 • 4-13

Inspect Siphon Break • 4-8

Change Engine Oil and Oil Filter—

• • 4-3
All except MDKBT &MDKBU
Change Engine Oil and Oil Filter—
• • 4-3
Only MDKBT &MDKBU
Replace Fuel Filters • 4-6

Inspect Zinc Anode • 4-8

Replace Raw Water Impeller • 4-12

Adjust Engine Valve Lash4 • −

Replace Coolant, Pressure Cap &

• 4-7
Thermostat
Inspect Generator Bearing4 • −

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).

4-1 Redistribution or publication of this document,

by any means, is strictly prohibited.
 GENERAL INSPECTION vided (see Installation Manual), open the sea valve
for the water drain hose.
Inspect the genset before the first start of the day
and after every eight hours of operation. Check for and replace hoses that leak or are dam-
aged.
Oil Level
Battery Connections
Check engine oil level (p. 4-3).
See MAINTAINING THE BATTERY AND BATTERY
Exhaust System CONNECTIONS.

Inspect the exhaust system for leaks and loose Mechanical

hose clamps at the exhaust manifold, exhaust el-
bow, muffler, water separator and hull fittings. Re- Monitor generator set status using the e-Series Dig-
place damaged sections of exhaust hose. ital Display (p. 2-4).

Check that all CO monitors are working properly. Look for mechanical damage and listen for unusual
noises when the genset is running. Check the gen-
WARNING EXHAUST GAS IS DEADLY! Do not set mounting bolts. Check to see that the genset air
operate the genset until all exhaust leaks have inlet and outlet openings are not clogged with debris
been repaired. or blocked. Keep the genset compartment clean.

Fuel System MAINTAINING THE BATTERY AND

BATTERY CONNECTIONS
Check for leaks at hose, tube and pipe fittings in the
fuel supply and return systems while the genset is WARNING Arcing at battery terminals or in
running and while it is stopped. Check flexible fuel light switches or other equipment, and flames or
hose for cuts, cracks, abrasions and loose hose sparks, can ignite battery gas causing severe
clamps. Make sure fuel lines do not rub against oth- personal injury—Ventilate battery area before
er parts. Replace worn or damaged fuel line parts working on or near battery—Wear safety
before leaks occur. Replace hose with with USCG glasses—Do not smoke—Switch work light ON
TYPE A1 or ISO 7840-A1 fuel hose. or OFF away from battery—Stop genset and dis-
connect charger before disconnecting battery
Prime the fuel system if the genset ran out of fuel. cables—Disconnect negative (−) cable first and
reconnect last.
WARNING Fuel leaks can lead to fire. Repair
leaks immediately. Do not run the genset if it Refer to Table 4-1 for scheduled battery mainte-
causes fuel to leak. nance, and follow the battery manufacturer’s in-
structions. Have the battery charging system ser-
Coolant Level viced if DC system voltage is consistently low or
high.
Check coolant level in the recovery tank and, if nec-
essary, refill the recovery tank to COLD when the Check the battery terminals for clean, tight connec-
engine is cold or to HOT when it is at normal running tions. Loose or corroded connections have high
temperature. The recovery tank is designed to electrical resistance which makes starting harder.
maintain coolant level, not to fill the system. If the Always:
tank is empty, check for and repair any coolant leaks 1. Keep the battery case and terminals clean and
and refill the system through the fill neck on the en- dry and the terminals tight.
gine. See Refilling the Cooling System (p. 4-8). 2. Remove battery cables with a battery terminal
Use the recommended antifreeze mixture (p. 3-1). puller.
Raw Water System 3. Make sure which terminal is positive (+) and
which is negative (−) before making battery
Clean out the sea water strainer if necessary and connections, always removing the negative (−)
make sure the sea valve is open for genset opera- cable first and reconnecting it last to reduce
tion. Also, when a water/exhaust separator is pro- arcing.

4-2 Redistribution or publication of this document,

by any means, is strictly prohibited.
 CHECKING ENGINE OIL LEVEL 2. Be ready to drain the oil into a suitable contain-
er and then open the drain valve or unscrew the
WARNING State and federal agencies have de- plug on the end of the drain hose (Figure 4-1,
termined that contact with used engine oil can 4-2 or 4-3) and drain the oil into a suitable con-
cause cancer or reproductive toxicity. Avoid tainer. (Two wrenches are necessary to keep
skin contact and breathing of vapors. Use rub- from twisting the hose when loosening and
ber gloves and wash exposed skin. tightening the plug.) If an oil pump-out system
is installed, follow the instructions provided.
CAUTION Too little oil can cause severe en-
3. Secure the drain plug or close the oil drain
gine damage. Too much oil can cause high oil
valve.
consumption.
4. Spin off the old oil filter with a filter wrench and
Shut off the genset and check the oil level with the wipe off the filter mounting surface. (A filter
dip stick (Figure 4-1, 4-2 or 4-3). Add or drain oil as wrench is available from Onan.) Remove the
necessary. Add 1 quart (0.9 liters) when the level old gasket if it does not come off with the filter.
falls to the ADD mark. Drain oil if the level is above
5. Apply a film of oil to the new filter gasket and
the full mark.
partly fill the new filter with oil so that it reaches
See ENGINE OIL RECOMMENDATIONS (p. 3-1). engine parts sooner at startup. Spin the filter on
by hand until the gasket just touches the mount-
CHANGING ENGINE OIL AND FILTER ing pad and tighten 3/4 turn.
6. Refill the engine with the proper type and
Refer to Table 4-1 for scheduled engine oil change.
amount of engine oil. See ENGINE OIL REC-
1. Run the genset under load until it is up to oper- OMMENDATIONS (p. 3-1) and Specifications
ating temperature, stop it and disconnect the (Section 6). Check the oil level and add or drain
negative (−) battery cable at the battery. oil as necessary. Run the engine for a few min-
WARNING Accidental or remote starting utes, shut it down and recheck for proper oil lev-
can cause severe personal injury or death. el.
Disconnect the negative (−) cable at the bat- 7. Dispose of the used oil and oil filter according
tery to prevent the engine from starting. to local environmental regulations.

4-3 Redistribution or publication of this document,

by any means, is strictly prohibited.
 OIL DIPSTICK OIL FILL

OIL DRAIN FUEL FILTER AND

HOSE WATER SEPARATOR OIl FILTER

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

OIL DIPSTICK
OIL FILL

FUEL FILTER AND

WATER SEPARATOR OIl FILTER

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

4-4 Redistribution or publication of this document,

by any means, is strictly prohibited.
 FUEL FILTER OIL DIPSTICK OIL FILL

OIL FILTER OIL DRAIN HOSE

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

4-5 Redistribution or publication of this document,

by any means, is strictly prohibited.
 DRAINING/REPLACING FUEL FILTERS Replacing Fuel Filters: See Table 4-1 for sched-
uled fuel filter replacement. Replace fuel filters (Fig-
WARNING Diesel fuel is combustible and can ure 4-1, 4-2 or 4-3) if the engine lacks power.
cause severe personal injury or death. Do not 1. Disconnect the negative (−) cable at the battery
smoke near fuel tanks or fuel-burning equip- to prevent the engine from starting and close
ment or in areas sharing ventilation with such any fuel supply and return valves.
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other WARNING Accidental or remote starting
sources of ignition well away. Keep a multi- can cause severe personal injury or death.
class ABC fire extinguisher handy. Disconnect the negative (−) cable at the bat-
tery to prevent the engine from starting.
Keep dirt, water and other contaminants from enter-
ing the fuel system and corroding or clogging fuel in- 2. Spin off the old filter with a filter wrench and dis-
jection components. pose of it in accordance with local environmen-
tal regulations.
Draining Water and Sediment: The genset may
3. Clean the contact surface on the filter base, lu-
have a water-separator type of fuel filter (Figure 4-1,
bricate the new filter gasket and spin the new
4-2). Also check for up-stream water-separator type
filter on hand tight.
fuel filters. Drain water and sediment more often
than scheduled (Table 4-1) if fuel quality is poor or 4. Prime the engine for at least 30 seconds
condensation cannot be avoided. Dispose of the (p. 3-3) to fill the new filter. Run the genset and
water, sediment and fuel drained off in accordance check for leaks. Tighten the filter by hand, if
with local environmental regulations. necessary.

4-6 Redistribution or publication of this document,

by any means, is strictly prohibited.
 MAINTAINING THE ENGINE COOLING sure (10 psi) is essential for optimal engine cooling
SYSTEM and minimal coolant loss.

Refer to Table 4-1 for scheduled maintenance. Coolant Hoses

Cooling System Overview
Check for and replace hoses that leak or are dam-
The engine is cooled by a pressurized, closed-loop aged.
liquid cooling system in which coolant is pumped
through passages in the engine block, head and ex- Draining and Cleaning Cooling System
haust manifold (Figure 4-4, 4-5or 4-6). Heat is car-
ried away from the coolant by a keel cooler or raw
water (sea water) heat exchanger. A gear-driven Have towels and containers ready to wipe up, col-
raw water pump is provided if the genset has a heat lect and properly dispose of the coolant. Disconnect
exchanger or wet exhaust. the negative (−) cable at the battery to prevent the
engine from starting and let the engine cool before
Keel Cooler: A keel cooler, when provided, is part removing the pressure cap.
of the pressurized, closed-loop liquid cooling sys-
tem through which the coolant flows. WARNING Accidental or remote starting can
Heat Exchanger: When a heat exchanger is pro- cause severe personal injury or death. Discon-
vided, raw water (the floatation water) is pumped nect the negative (−) cable from the battery to
through tubes in the heat exchanger to cool the en- prevent the engine from starting.
gine coolant. The water is then passed through a
hose into the exhaust-water mixer to cool the ex- Hot coolant spray can cause severe burns. Let
haust gases. The raw water is expelled from the the engine cool before releasing the pressure
boat along with the exhaust gases. cap or removing the drain cap.

Recommended Coolant Mixture Remove the pressure cap and open the block and
heat exchanger drain valves (Figure 4-4, 4-5or 4-6)
See ENGINE COOLANT (p. 3-1) for recommenda-
and drain the coolant into suitable containers for dis-
tions.
posal in accordance with the local regulations for
Replenishing Normal Coolant Loss hazardous substances.

Check coolant level in the recovery tank before the Drain or flush a keel cooler in accordance with the
first startup of each day and, if necessary, refill to manufacturer’s instructions.
COLD when the engine is cold or to HOT when it is
running. The recovery tank is designed to maintain Use radiator cleaning chemicals to clean and flush
coolant level, not to fill the system. If the tank is the cooling system before refilling with fresh cool-
empty, check for and repair any coolant leaks and ant. Follow the cleaner manufacturer’s instructions.
refill the system through the fill neck on the engine.

Pressure Cap CAUTION Filling a hot engine with cold water

can cause cracks in the manifold, head and
Replace the pressure cap every two years (seals block. Follow the manufacturer’s instructions
deteriorate and leak). Proper cooling system pres- for cleaning and flushing.

4-7 Redistribution or publication of this document,

by any means, is strictly prohibited.
Refilling Cooling System formed. Torque the strap screws as specified in
Figure 4-6.
Close the block and heat exchanger drain valves
and fill the system through the engine fill neck. The Zinc Anode
system will fill only as fast as the air can escape. Fill
to the bottom of the fill neck. Start and run the engine Replace the zinc anode as recommended
for a couple of minutes to dislodge air pockets and (Table 4-1). Use thread sealant on the zinc plug and
shut it down. Add as much coolant as necessary drain plugs and replace the clean out cover gaskets
and secure the pressure cap. Then refill the recov- if the old ones are torn or otherwise damaged.
ery tank up to the COLD mark.
Siphon Break
CAUTION Low coolant level can cause severe
engine damage. Make sure the system is full. See Table 4-1 for scheduled maintenance. A siphon
break is installed when the exhaust-water mixer is
Heat Exchanger below the water line. If of a spring-loaded valve de-
sign, check for free movement of the plunger. Re-
Both ends of the heat exchanger (Figure 4-4, 4-5 or place the device if the plunger does not move freely
4-6) have raw water drain plugs and cleanout cov- or the body is encrusted with deposits from leakage
ers. Clean the raw water tubes if the engine keeps past the valve seat. If of the bleed-vent type, check
shutting down (Code No.1). Drain the heat ex- that the vent hose is properly connected on both
changer if there is a danger of freezing when the ends. If the vent is connected to a through-hull fit-
genset is not running or is in storage. (Freezing wa- ting, check for normal water flow whenever the en-
ter can damage the raw water tubes in the heat ex- gine is running. See the Installation Manual for more
changer. Engine coolant, but not raw water, is pro- information regarding siphon break installation.
tected from freezing.)
WARNING Bypassing a siphon break or failing
CAUTION Models MDKBT and MDKBU—Do to maintain it can lead to engine flooding and
not overtighten the heat exchanger mounting damage to the engine not covered under War-
straps or the heat exchanger could be de- ranty.

4-8 Redistribution or publication of this document,

by any means, is strictly prohibited.
 OPTIONAL LOW COOLANT
LEVEL SENSOR LOCATION

COOLANT
THERMOSTAT

COOLANT PUMP

RAW WATER PUMP

RAW WATER FLOW SENSOR

RAW WATER IN FROM

BULKHEAD FITTING ON EXHAUST MANIFOLD & COOLANT RESERVOIR
RIGHT OR LEFT SIDE WITH PRESSURE CAP AND COOLANT FILL
NECK. FILL NECK HAS HOSE BARB FOR
CONNECTING COOLANT RECOVERY TANK

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

BLOCK DRAIN VALVE

(COOLANT)

COOLANT RAW WATER CLEANOUT

DRAIN COVER (BOTH ENDS)
VALVE COOLANT
ZINC RAW WATER DRAIN PLUG
ANODE (BOTH ENDS) RAW WATER

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

4-9 Redistribution or publication of this document,

by any means, is strictly prohibited.
 RAW WATER TO PUMP FROM COOLANT RESERVOIR WITH PRESSURE CAP AND
BULKHEAD FITTING ON COOLANT FILL NECK. FILL NECK HAS HOSE BARB
RIGHT OR LEFT SIDE FOR CONNECTING COOLANT RECOVERY TANK

LOCATION, OPTIONAL LOW

COOLANT LEVEL SENSOR

COOLANT
THERMOSTAT
HOUSING

COOLANT
TEMPERATURE
SENSOR
RAW
WATER
PUMP
COOLANT
PUMP PULLEY

RAW WATER HOSE TO

EXHAUST-WATER
MIXER—WHEN REQUIRED, LOCATION, BLOCK
REPLACE WITH SIPHON DRAIN VALVE
BREAK AND CONNECTING (COOLANT)
HOSES
RAW WATER FLOW SWITCH
(IN PUMP-TO-HEAT EXCHANGER HOSE) ZINC ANODE

EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT
OR LEFT SIDE

RAW WATER CLEANOUT COVER

COOLANT DRAIN VALVE (BOTH ENDS—MAKE SURE TO COOLANT
RAW WATER PLUGS RECONNECT GROUND STRAP ON
(UNDERNEATH) THIS END WITH COVER SCREW) RAW WATER

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

4-10 Redistribution or publication of this document,

by any means, is strictly prohibited.
 HOSE, THERMOSTAT TO
COOLANT RESERVOIR

HOSE, RAW WATER TO

EXHAUST-WATER MIXER*

HOSE, COOLANT
RESERVOIR TO
HEAT EXCHANGER HOSE, HEAT
EXCHANGER TO
COOLANT PUMP
LOCATION,
RAW WATER
ZINC FLOW SWITCH
ANODE

HOSE, RAW WATER PUMP

TO HEAT EXCHANGER

HEAT EXCHANGER
MOUNTING STRAPS (2) RAW
TORQUE TO 8 FT−LB (11 N-M) WATER
PUMP

COOLANT
DRAIN VALVE

HEAT EXCHANGER WITH CLEANOUT RAW WATER COOLANT

COVERS, TOP & BOTTOM DRAIN PLUG RAW WATER

* 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 Redistribution or publication of this document,

by any means, is strictly prohibited.
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 bat- MDKBP, MDKBR, MDKBS
tery to prevent the engine from starting.

3. Loosen the three screws on the end of the

pump body to remove the pump body or impel-
ler cover, depending on construction (Fig-
ure 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 suc-
tion before water reaches the pump, wet the in-
side of the pump and impeller with water, soap MDKBK, MDKBL, MDKBM, MDKBN
solution or a silicone lubricant. It also helps to
twist the impeller while squeezing it into the
housing.

CAUTION Do not lubricate the impeller

with grease or oil or other petroleum prod-
ucts 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 MDKBT, MDKBU

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. FIGURE 4-7. TYPICAL RAW WATER PUMPS

4-12 Redistribution or publication of this document,

by any means, is strictly prohibited.
Adjusting V-Belt Tension
TENSION
The V-belt drives the battery charging alternator and ADJUSTING
BOLT
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.
ALTERNATOR
WARNING Accidental or remote starting PIVOT BOLT
can cause severe personal injury or death.
Disconnect the negative (−) cable at the bat-
tery 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. 3/8 INCH (10 MM)
Belt tension is correct when deflection is DEFLECTION @
3/8 inch (10 mm). Tighten the alternator bolts 20 LBS (10 KG)
when tension is correct.
5. Tighten the bolts, secure the belt guard or en-
closure and reconnect the battery cables (neg- FIGURE 4-8. ADJUSTING V-BELT TENSION
ative [−] 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 dur-
ing 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.

4-13 Redistribution or publication of this document,

by any means, is strictly prohibited.
Replacing the Thermostat
See Table 4-1 for scheduled replacement. Refer-
ring 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 en-
gine cool and remove the front and back access
doors if the genset has an enclosure.
WARNING ACCIDENTAL OR REMOTE
STARTING can cause severe personal inju-
ry or death. Disconnect the negative (−)
cable from the battery to prevent the engine THERMOSTAT
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 FIGURE 4-9. TYPICAL THERMOSTAT
gasket.
5. Replenish any lost coolant, secure the pres-
sure cap and any doors and panels removed
and reconnect the battery cables (negative [−]
last).

4-14 Redistribution or publication of this document,

by any means, is strictly prohibited.
5. Troubleshooting
Use TABLE 5-1. TROUBLESHOOTING GENSET TROUBLESHOOTING WITH STATUS LAMP
FAULTS in conjunction with the e-Series Digital Dis-
play or blinking control switch status lamp to trouble- If a fault shutdown occurs, the amber status lamp on
shoot the genset. Perform the step-by-step correc- the control switch will repeatedly blink sets of 3, 4, 5
tive actions suggested. If you are still unable to re- or 7 blinks.
solve the problem, contact an authorized Onan ser- • One blink indicates shutdown due to high en-
vice representative. See How to Obtain Service gine temperature.
(p. 1-2).
• Two blinks indicate shutdown due to low oil
pressure.
Note:Many genset shutdowns can be avoided by per- • Three blinks indicate a service fault. Press
forming periodic maintenance on schedule Stop once to cause the two-digit shutdown
(TABLE 4-1. PERIODIC MAINTENANCE SCHEDULE)
code to blink. (Pressing Stop again will stop the
and by not running the genset out of fuel. Note that
when gensets and propulsion engines draw from the blinking.) The two-digit code consists of 1 to 7
same fuel tanks, the fuel pickup tubes are usually ar- blinks, a brief pause, and then 1 to 9 blinks. The
ranged so that the gensets run out of fuel first. By first set of blinks represents the tens digit and
marking the genset empty points on the fuel gauges, the second set of blinks the units digit of the
it will be easier to tell when to stop the gensets before shutdown code number. For example, Low
running them out of fuel. Voltage Code No. 13 appears as: blink—
pause—blink-blink-blink—long pause—re-
peat
TROUBLESHOOTING WITH DIGITAL
• Four blinks indicate shutdown due to a failure
DISPLAY
to start within the time allowed for cranking.
• Five blinks indicate shutdown due to high lev-
If a fault shutdown occurs the ALARM status lamp els of Carbon Monoxide (CO) in the vessel.
on the e-Series Digital Display will blink and the LCD • Seven blinks indicate shutdown due to a loss
screen will display the Fault Number, a description of raw water flow for engine and exhaust cool-
of the Fault and the hour in total genset running time ing.
when the Fault occurred (Figure 2-4).
Blinking continues for five minutes and stops. To re-
store blinking press the control switch to STOP
The fault will be displayed until it is cleared. Touch (Prime) until the lamp comes on (3 to 4 seconds).
any button to clear the fault. The display will turn off Then press STOP (Prime) three times to restores
in 5 minutes after the fault has been cleared. blinking.
Note:The last fault logged will blink even though the
Last Five Faults: See Page 2-6 to display any of condition that caused the shutdown may have been
the last five faults in fault history. corrected.

5-1 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 Dis-
play 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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 fre-
quency.)
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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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.

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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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.

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 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 Redistribution or publication of this document,

by any means, is strictly prohibited.
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 0.8 gph (3.0 liter/hr) 0.8 gph (3.0 liter/hr) 1.0 gph (3.8 liter/hr) 1.2 gph (4.5 liter/hr)
Half Load 0.5 gph (1.9 liter/hr) 0.5 gph (1.9 liter/hr) 0.6 gph (2.3 liter/hr) 0.7 gph (2.7 liter/hr)
50 Hz: Full Load 0.7 gph (2.7 liter/hr) 0.7 gph (2.7 liter/hr) 0.8 gph (3.0 liter/hr) 0.9 gph (3.4 liter/hr)
Half Load 0.4 gph (1.5 liter/hr) 0.4 gph (1.5 liter/hr) 0.5 gph (1.9 liter/hr) 0.5 gph (1.9 liter/hr)
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
0.0071 − 0.0087 in 0.0071 − 0.0087 in 0.0071 − 0.0087 in 0.0071 − 0.0087 in
Valve Lash (cold) (0.18 − 0.22 mm) (0.18 − 0.22 mm) (0.18 − 0.22 mm) (0.18 − 0.22 mm)
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 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9liter/min)
50 Hz 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min)
Raw Water Flow Rate: 60 Hz 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min)
50 Hz 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min)
Combustion Air Flow: 60 Hz 30 cfm (0.85 m3/min) 30 cfm (0.85 m3/min) 36 cfm (1.02 m3/min) 41 cfm (1.16 m3/min)
50 Hz 25 cfm (0.71 m3/min) 25 cfm (0.71 m3/min) 30 cfm (0.85 m3/min)) 34 cfm (0.96 m3/min)
Heat Rejection to Ambient: 60 Hz 200 Btu/min (50 kcal/min) 200 Btu/min (50 kcal/min) 230 Btu/min (58 kcal/min) 280 Btu/min (71 kcal/min)
50 Hz 179 Btu/min (45 kcal/min) 179 Btu/min (45 kcal/min) 190 Btu/min (48 kcal/min) 210 Btu/min (53 kcal/min)
Maximum Angularity 10° Continuous, 22.5° Intermittent
Recommended Fuel No. 2-D Diesel Fuel: Spec EN 590 or ASTM D975
Ethylene Glycol: Spec ASTM D5345 for 50/50 Prediluted Coolant or
Recommended Coolant ASTM D4985 for Concentrated Coolant with 40% to 60% quality water
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 950 Btu/min (239 kcal/min) 950 Btu/min (239 kcal/min) 1220 Btu/min (307 kcal/min) 1420 Btu/min (358 kcal/min)
50 Hz 780 Btu/min (197 kcal/min) 780 Btu/min (197 kcal/min) 980 Btu/min (247 kcal/min) 1160 Btu/min (292 kcal/min)
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 525 lbs (238 kg) 555 lbs (252 kg) 640 lbs (290 kg) 640 lbs (290 kg)
Dimensions: L x W x H 32.4 x 18.9 x 22.1 in 35.9 x 22.3 x 23.0 in 40.7 x 22.3 x 23.0 in 40.7 x 22.3 x 23.0 in
(479.1 x 822.6 x 560.9 mm) (911 x 566 x 585 mm) (1033 x 566 x 585 mm) (1033 x 566 x 585 mm)
With Enclosure
Noise − 66/65 dB(A) @ 60/50HZ 66/65 dB(A) @ 60/50HZ 66/65 dB(A) @ 60/50HZ
Dry Weight 600 lbs (272 kg) 695 lbs (315 kg) 695 lbs (315 kg)
Dimensions: L x W x H 35.9 x 22.3 x 23.4 in 40.7 x 22.3 x 23.4 in 40.7 x 22.3 x 23.4 in
(911 x 566 x 593 mm) (1033 x 566 x 593 mm) (1033 x 566 x 593 mm)

6-1 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 1.3 gph (4.9 liter/hr) 1.9 gph (7.2 liter/hr) 2.5 gph (9.5 liter/hr)
Half Load 0.8 gph (3.0 liter/hr) 1.1 gph (4.2 liter/hr) 1.5 gph (5.7 liter/hr)
50 Hz: Full Load 1.1 gph (4.2 liter/hr) 1.6 gph (6.1 liter/hr) 2.1 gph (8.0 liter/hr)
Half Load 0.7 gph (2.7 liter/hr) 0.9 gph (3.4 liter/hr) 1.3 gph (4.9 liter/hr)
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
0.0071 − 0.0087 in 0.0071 − 0.0087 in 0.0071 − 0.0087 in
Valve Lash (cold) (0.18 − 0.22 mm) (0.18 − 0.22 mm) (0.18 − 0.22 mm)
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 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min)
50 Hz 10.0 gpm (37.9 liter/min) 10.0 gpm (37.9 liter/min)) 10.0 gpm (37.9 liter/min)
Raw Water Flow Rate: 60 Hz 9.0 gpm (34.1 liter/min) 9.0 gpm (34.1 liter/min) 9.0 gpm (34.1 liter/min)
50 Hz 7.0 gpm (26.5 liter/min) 7.0 gpm (26.5 liter/min) 7.0 gpm (26.5 liter/min)
Combustion Air Flow: 60 Hz 52 cfm (1.45 m3/min) 60 cfm (1.72 m3/min) 75 cfm (2.12 m3/min)
50 Hz 42 cfm (1.21 m3/min) 50 cfm (1.43 m3/min)) 63 cfm (1.78 m3/min)
Heat Rejection to Ambient: 60 Hz 350 Btu/min (88 kcal/min) 420 Btu/min (106 kcal/min) 530 Btu/min (134 kcal/min)
50 Hz 285 Btu/min (72 kcal/min) 350 Btu/min (88 kcal/min) 450 Btu/min (114 kcal/min)
Maximum Angularity 10° Continuous, 22.5° Intermittent
Recommended Fuel No. 2-D Diesel Fuel: Spec EN 590 or ASTM D975
Ethylene Glycol: Spec ASTM D5345 for 50/50 Prediluted Coolant or
Recommended Coolant ASTM D4985 for Concentrated Coolant with 40% to 60% quality water
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 1590 Btu/min (402 kcal/min) 1980 Btu/min (500 kcal/min) 2490 Btu/min (629 kcal/min)
50 Hz 1500 Btu/min (379 kcal/min) 1670 Btu/min (422 kcal/min) 2090 Btu/min (528 kcal/min)
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 830 lbs (377 kg) 870 lbs (375 kg) 1090 lbs (494 kg)
Dimensions: L x W x H 44.4 x 23.7 x 26.1 in 44.4 x 23.7 x 26.1 in 53.5 x 23.7 x 28.8 in
(1127 x 602 x 663 mm) (1127 x 602 x 663 mm) (1358 x 602 x 732 mm)
With Enclosure
Noise 67/64 dB(A) @ 60/50 HZ 67/64 dB(A) @ 60/50 HZ 68/67 dB(A) @ 60/50 HZ
Dry Weight 890 lbs (404 kg) 930 lbs (422 kg) 1175 lbs (533 kg)
Dimensions: L x W x H 44.4 x 23.7 x 27.5 in 44.4 x 23.7 x 27.5 in 53.5 x 23.7 x 30.0 in
(1127 x 602 x 698 mm) (1127 x 602 x 698 mm) (1358 x 602 x 763 mm)

6-2 Redistribution or publication of this document,

by any means, is strictly prohibited.
 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 2.5 gph (9.5 liter/hr) 3.0 gph (11.2 liter/hr)
Half Load 1.5 gph (5.7 liter/hr) 1.5 gph (5.6 liter/hr)
50 Hz: Full Load 2.1 gph (8.0 liter/hr) 2.4 gph (9.1 liter/hr)
Half Load 1.5 gph (5.6 liter/hr) 1.5 gph (5.7 liter/hr)
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
0.009 − 0.010 in 0.009 − 0.010 in
Valve Lash (cold) (0.23 − 0.27 mm) (0.23 − 0.27 mm)
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 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min)
50 Hz 11.5 gpm (43.5 liter/min) 11.5 gpm (43.5 liter/min)
Raw Water Flow Rate: 60 Hz 15.6 gpm (59.1 liter/min) 15.6 gpm (59.1 liter/min)
50 Hz 13.0 gpm (49.2 liter/min) 13.0 gpm (49.2 liter/min)
Combustion Air Flow: 60 Hz 91.7 cfm (2.6 m3/min) 91.7 cfm (2.6 m3/min)
50 Hz 76.5 cfm (2.2 m3/min) 76.5 cfm (2.2 m3/min)
Heat Rejection to Ambient: 60 Hz 532 Btu/min (134 kcal/min) 629 Btu/min (159 kcal/min)
50 Hz 441 Btu/min (111 kcal/min) 515 Btu/min (130 kcal/min)
Maximum Angularity 10° Continuous, 22.5° Intermittent
Recommended Fuel No. 2-D Diesel Fuel: Spec EN 590 or ASTM D975
Ethylene Glycol: Spec ASTM D5345 for 50/50 Prediluted Coolant or
Recommended Coolant ASTM D4985 for Concentrated Coolant with 40% to 60% quality water
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 2200 Btu/min (555 kcal/min) 2600 Btu/min (655 kcal/min)
50 Hz 1870 Btu/min (470 kcal/min) 2200 Btu/min (555 kcal/min)
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
12 volts: 30.0/22.0 amps (60/50 Hz) 12 volts: 30.0/22.0 amps (60/50 Hz)
Net Battery Charging (Negative Ground) 24 volts: 22.5/20.5 amps (60/50 Hz) 24 volts: 22.5/20.5 amps (60/50 Hz
12 volts: 43.0/40.0 amps (60/50 Hz) 12 volts: 43.0/40.0 amps (60/50 Hz)
Net Battery Charging (Isolated Ground) 24 volts: 30.5/28.5 amps (60/50 Hz) 24 volts: 30.5/28.5 amps (60/50 Hz)
SIZE, WEIGHT, NOISE:
Without Sound Shield
Dry Weight 1245 lbs (565 kg) 1300 lbs (590 kg)
Dimensions: L x W x H 53.5 x 24.5 x 28.8 in (1358 x 622 x 731 mm) 53.5 x 24.5 x 28.8 in (1358 x 622 x 731 mm)
With Sound Shield
Noise 68/67 dB(A) @ 60/50 HZ 68/67 dB(A) @ 60/50 HZ
Dry Weight 1325 lbs (601 kg) 1380 lbs (626 kg)
Dimensions: L x W x H 53.5 x 24.5 x 30.0 in (1358 x 622 x 761 mm) 53.5 x 24.5 x 30.0 in (1358 x 622 x 761 mm)

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7. Maintenance Record

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

HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING

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

7-1 Redistribution or publication of this document,

by any means, is strictly prohibited.
This side is intentionally blank

Redistribution or publication of this document,

by any means, is strictly prohibited.