MDKAU Service Manual PDF

Service Manual
Marine Generator Set
MDKAU (Spec A−C)
English − English Original 4−2010 981−0532 (Issue 4)

Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Starting and Stopping the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Changing Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Draining / Changing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Maintaining Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4. ENCLOSURE, DRIP PAN AND MOUNTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Drip Pan and Mounting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
5. CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Controller A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Control Switch S4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Emergency Switch/Breaker CB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hour Meter M11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Line Circuit Breaker CB3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Oil Pressure Sender E1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Engine Coolant Temperature Sender E2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Raw Water Flow Switch S6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
High Exhaust Temperature Switch S5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Glow Plug Relay K3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Battery Charging Regulator AVR1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Ground Isolation Relay K9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
i
SECTION PAGE
6. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Servicing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Servicing Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Testing Field Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Testing Generator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Reconnecting the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Adjusting Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
7. GENERATOR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Inspecting Drive and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8. ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Major Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Intake Resonator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
9. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
ii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL • Make sure all fasteners are secure and proper-
before operating the genset. Safe operation and ly torqued.
top performance can only be attained when
• Do not work on the genset when mentally or
equipment is operated and maintained properly.
physically fatigued or after having consumed
alcohol or drugs.
The following symbols in this manual alert you to po-
tential hazards to operators, service personnel and • You must be trained and experienced to make
equipment. adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
DANGER alerts you to an immediate hazard vere personal injury or death.
which will result in severe personal injury or • Used engine oil has been identified by some
death. U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
WARNING alerts you to a hazard or unsafe inhale, or contact used oil or its vapors.
practice which can result in severe personal in-
jury or death. • Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
CAUTION alerts you to a hazard or unsafe
dance with local environmental regulations.
practice which can result in personal injury or
equipment damage. • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
Electricity, fuel, exhaust, hot engine coolant, moving terials such as wood and cloth; Class B fires,
parts and batteries present hazards which can re- combustible and flammable liquid fuels and
sult in severe personal injury or death. gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
GENERAL PRECAUTIONS • Genset installation and operation must comply
• Keep children away from the genset. with all applicable local, state and federal codes
and regulations.
• Do not step on the genset when entering or
leaving the generator room. Parts can bend or GENERATOR VOLTAGE IS DEADLY
break leading to electrical shorts or to fuel, cool- • Generator electrical output connections must
ant or exhaust leaks. be made by a trained and experienced electri-
• To prevent accidental or remote starting while cian in accordance with applicable codes.
working on the genset, disconnect the nega- • The genset must not be connected to shore
tive (−) battery cable at the battery. power or to any other source of electrical pow-
• Let the engine cool down before removing the er. Back-feed to shore power can cause electric
coolant pressure cap or opening the coolant shock resulting in severe personal injury or
drain. Hot coolant under pressure can spray death and damage to equipment. An approved
and cause severe burns. switching device must be used to prevent inter-
connections.
• Do not use evaporative starting fluids. They are
• Use caution when working on live electrical
highly explosive.
equipment. Remove jewelry, make sure cloth-
• Keep the genset, drip pan and compartment ing and shoes are dry, stand on a dry wooden
clean. Oily rags can catch fire. Gear stowed in platform or rubber insulating mat and use tools
the compartment can restrict cooling. with insulated handles.
iii
ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE
• Never sleep in the boat while the genset is run- • Wear safety glasses while servicing batteries
ning unless the boat is equipped with properly and do not smoke.
working carbon monoxide detectors. • To reduce arcing when disconnecting or recon-
• The exhaust system must be installed in accor- necting battery cables, always disconnect the
dance with the genset Installation Manual and negative (−) battery cable first and reconnect it
be free of leaks. last.
• Make sure the bilge is adequately ventilated MOVING PARTS CAN CAUSE SEVERE
with a power exhauster. PERSONAL INJURY OR DEATH
• Inspect for exhaust leaks every startup and af- • Do not wear loose clothing or jewelry near mov-
ter every eight hours of operation. ing parts such as PTO shafts, fans, belts and
• For more information about carbon monoxide pulleys.
see American Boat and Yacht Council (ABYC) • Keep hands away from moving parts.
publication TH-22—Educational Information
• Keep guards in place over fans, belts, pulleys,
About Carbon Monoxide.
and other moving parts.
DIESEL FUEL IS COMBUSTIBLE FLAMMABLE VAPOR ENVIRONMENT
• Do not smoke or turn electrical switches ON or
Flammable vapor can cause a diesel engine to
OFF where fuel fumes are present or in areas
overspeed and become difficult to stop, resulting in
sharing ventilation with fuel tanks or equip-
possible fire, explosion, severe personal injury or
ment. Keep flames, sparks, pilot lights, arc-pro-
death. Do not operate a diesel-powered genset
ducing equipment and all other sources of igni-
in a flammable vapor environment created by
tion well away.
fuel spill, leak, etc. The owners and operators of
• Fuel lines must be secured, free of leaks and the genset are solely responsible for operating the
separated or shielded from electrical wiring. genset safely.
POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE BOAT

M-10
iv
1. Introduction
ABOUT THIS MANUAL
This is the service manual for the MDKAU Series of
generator sets (gensets). Read and carefully ob-
serve all of the instructions and precautions in this
manual.
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.
WARNING Unauthorized modifications or re-

placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of 5MDKAU-667A
California. I000 123456
See the Installation Manual for important recom-

mendations concerning the installation and for a list
of the installation codes and standards for safety
which may be applicable.
See the Parts Manual for part identification numbers

and required quantities and for exploded views of
the genset subassemblies. Genuine Onan® re-
placement parts are recommended for best results.
When contacting Onan for parts and product infor-

mation, be ready to provide the model and serial
numbers on the genset nameplate. Figure 1-1 illus- FIGURE 1-1. TYPICAL NAMEPLATE
trates the nameplate and its location. The numbers
in the gray boxes are typical model and serial num-
bers. Every character in these numbers is signifi-
cant. (The last character of the model number is the
specification letter, which is important for obtaining
the right parts.)
1-1
FUEL RECOMMENDATIONS
High quality fuel is necessary for good performance
and long engine life. Use No. 2 diesel fuel (American
Society for Testing and Materials [ASTM]
Grade 2-D). The Cetane number should not be less
than 45 and sulfur content not more than 0.5 percent
(by weight). Where fuel is exposed to cold ambient
temperatures, use fuel that has a cloud point (tem-
perature at which wax crystals begin to form) at
least 10° F (6° C) degrees below the lowest ex-
pected fuel temperature. FIGURE 1-2. SAE VISCOSITY GRADE vs. AMBIENT
WARNING Diesel fuel is combustible and can TEMPERATURE
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.
ENGINE OIL RECOMMENDATIONS
Use API (American Petroleum Institute) perfor-
mance Class CH-4, CG-4 or CF-4 engine oil, which
may be in combination with performance Class SJ,
SH or SG (for example: SJ/CH-4). Also look for the
SAE (Society of Automotive Engineers) viscosity
grade. Referring to Figure 1-2, 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.
STARTING BATTERIES
The genset requires a 12 volt battery to power its
control and starting circuits. Reliable genset starting
and starter service life depend upon adequate bat-
tery system capacity and maintenance. See Specifi-
cations (Page 1-3) for battery requirements and
Periodic Maintenance (Page 3-6) for battery care.
1-2
SPECIFICATIONS
GENERATOR: Two-Bearing, 2-Pole Rotating Field, Microprocessor Regulated. See Genset Nameplate for Rating
FUEL CONSUMPTION:
60 Hz: Full Load 0.60 gph (2.3 liter/hr)
Half Load 0.35 gph (1.3 liter/hr)
50 Hz: Full Load 0.50 gph (1.9 liter/hr)
Half Load 0.29 gph (1.1 liter/hr)
Engine/Generator Speed:
2900/3600 rpm
60 Hz
2400/3000 rpm
50 Hz
ENGINE: 4-Stroke Cycle, Indirect Injection Diesel, Water Cooled, Microprocessor Governed (Isochronous)
Number of Cylinders 2
Bore 2.52 inch (64 mm)
Stroke 2.45 inch (62.2 mm)
Displacement 24.41 inch3 (400 cm3)
Compression Ratio 23:1
Firing Order (Clockwise Rotation) 1-2
Fuel Injection Timing 18° − 20° BTDC
Fuel Injection Pressure 1991 psi (13.73 MPa)
Valve Lash (cold) 0.0059 − 0.0073 INCH (0.145 − 0.185 MM)
Engine Oil Capacity 2.2 quart (2.1 liter)
Engine Oil Drain Connection 3/8 NPT
Coolant Capacity 2.2 quart (2.1 liter)
Coolant Flow: 60 Hz 3.5 gpm (13 liter/min)
50 Hz 3.0 gpm (16 liter/min)
Raw Water Flow: 60 Hz 5.0 gpm (19 liter/min)
50 Hz 4.0 gpm (15 liter/min)
Maximum Raw Water Pump Lift 4 feet (1.2 m) with 5/8 inch ID hose
Raw Water Inlet Connection 5/8 inch (15.9 mm) ID Hose
Maximum Fuel Pump Lift 4 feet (1.2 m) with 3/8 inch ID fuel line
Recommended Fuel Line Size 3/8 inch (9 mm) ID
Fuel Supply Connection 1/8 NPT female
Fuel Return Connection 1/8 NPT female
Maximum Exhaust Back Pressure 3 INCH (76 MM) HG
Wet Exhaust Outlet Connection 2.0 INCH (50.8 MM) ID HOSE
Combustion Air 18 CFM (30 M3/HR)
Generator Cooling Air 60-80 CFM (100-135 M3/HR)
BATTERIES:
Nominal Battery Voltage 12 volts
Minimum CCA Rating 360 amps
Battery Charging Output 10 amps
SIZE, WEIGHT, NOISE:
Size: L x W x H 26 x 20.1 x 20.6 inch (662 x 511 x 524 mm)
Weight (dry) 350 lbs (159 kg)
Noise: 60 Hz 71 dB(A)
50 Hz 68 dB(A)
1-3
2. Operation
CONTROL PANEL cate the cause of shutdown. See Troubleshooting
(Page 9-1). The green status lamp lights when the
Genset (Local) Control Panel engine is up to speed and stays on while the genset
runs.
The control panel is located in the front, upper left
hand corner of the genset (Figure 2-1). Emergency Stop Switch − In an emergency, push
this rocker switch to STOP. Push the switch to RUN
Control Switch − This switch is used to prime the after all necessary repairs to the genset and con-
fuel system, start and stop the genset and display nected equipment have been made.
the shutdown codes.
Line Circuit Breaker − The line circuit breaker pro-
• Hold the switch in its START position to pre-
tects the AC power leads connected to the genset
heat, crank and start the genset. (Preheat is the
from overloads and equipment short circuits.
period of time prior to engine cranking when the
glow plugs preheat the combustion chambers.
Hour Meter − The hour meter records genset oper-
The time is automatically varied by the genset
ating time in hours. It cannot be reset.
controller on the basis of engine temperature.)
• Press the switch to its STOP(Prime) position to Oil Fill Neck− The oil fill neck is located on the con-
stop the genset. trol panel. The fill plug has a flexible dipstick at-
tached for checking engine oil level.
• Hold the switch in its STOP(Prime) position to
prime the fuel system (starts in 2 seconds).
Remote Control Panel
• See Troubleshooting (Page 9-1) about display-
ing the shutdown codes. The boat probably has one or two remote control
panels for starting and operating the genset. Panels
Status Indicator Lamps− There are two LED (light with Onan engine gauges have green, yellow and
emitting diode) lamps in the control switch. The am- red LEDs. GREEN indicates normal operation.
ber status lamp lights during priming, blinks rapidly YELLOW and RED warn of an abnormal engine
during pre-heat and cranking and goes out when the condition requiring maintenance or service. RED is
engine is up to speed. If the genset shuts down ab- more severe than YELLOW. See Periodic Mainte-
normally, this lamp will slowly blink a code to indi- nance (Page 3-1).
LINE CIRCUIT BREAKER
CONTROL SWITCH &

STATUS INDICATOR LAMPS
EMERGENCY
STOP SWITCH
HOUR METER OIL FILL NECK
FIGURE 2-1. GENSET CONTROL PANEL
2-1
WARNING EXHAUST GAS IS DEADLY!
Engine exhaust contains carbon monoxide, a poisonous, odorless and colorless gas that can cause
unconsciousness and death. Symptoms of carbon monoxide poisoning include:
• Dizziness • Throbbing in Temples • Nausea
• Muscular Twitching • Headache • Vomiting
• Weakness • Trouble Thinking Clearly • Sleepiness
GET EVERYONE OUT INTO FRESH AIR IMMEDIATELY IF ANYONE EXPERIENCES ANY OF THESE
SYMPTOMS. Seek medical attention if symptoms persist. Never sleep in the boat when the genset is
running unless the cabin has a working carbon monoxide detector.
Look over the entire exhaust system and listen for leaks every time you start up the genset and after
every eight hours of operation. Shut down the genset immediately if there is a leak. Do not run the
genset until the leak has been repaired. The exhaust system must be installed in accordance with the
genset Installation Manual.
STARTING AND STOPPING THE GENSET 2. For longer engine life, let the engine warm up
for two minutes before turning on air condition-
Pre-Start Checks ers and other large appliances.
3. Check for water, coolant, fuel and exhaust
Conduct general inspections (Page 3-2) before the leaks. Stop the genset immediately if there is a
first start of the day and after every eight hours of op- leak. Repair fuel leaks immediately.
eration. Perform periodic maintenance that may be
4. Monitor the engine gauges if the remote control
due and maintenance required to return the genset
panel is so equipped. Perform maintenance or
to service if the boat has been in storage. Before
service as necessary if a gauge indicates an
each start:
abnormal engine condition. See Periodic Main-
1. Make sure all CO detectors on board are work- tenance (Page 3-1).
ing properly. 5. If the genset fails to start, cranking will dis-
2. Check for swimmers that might be exposed to continue in 20 to 60 seconds, depending on
the engine exhaust. how cold the engine is, and the amber status
lamp will blink Shutdown Code No. 4
3. Turn off air conditioners and other large ap- (Page 9-5). See Troubleshooting (Page 9-1) if
pliances. the genset does not start after two or three tries.
CAUTION Do not continue cranking and
Priming the Fuel System
risk burning out the starter or flooding the
If the genset ran out of fuel, prime the fuel system by engine (exhaust flow during cranking is too
holding the control switch at STOP/PRIME for low to expel water from the exhaust sys-
30 seconds. (The amber status lamp will light.) tem). Find out why the genset does not start
and make necessary repairs.
Starting the Genset 6. If the genset shuts down, the amber status
lamp will blink one of the shutdown codes. See
1. Push and hold the control switch at START until Troubleshooting (Page 9-1).
the genset starts. The amber status lamp will
blink rapidly. The amber status lamp will go out Stopping the Genset
and the green status lamp will light when the
engine is up to speed. (Depending on how cold Turn off air conditioners and other large appliances
the engine is, preheat can take up to 15 sec- and let the genset run for two minutes to cool down.
onds before cranking starts.) Then touch the Control Switch to STOP(Prime).
2-2
Emergency Stop not operating. Freezing water can damage the raw
water tubes in the heat exchanger. Engine coolant,
Push the EMERGENCY STOP SWITCH to STOP but not raw water, is protected from freezing. Drain
(Page 2-1). After all necessary repairs have been the heat exchanger if there is a danger of freezing.
made, push the switch to RUN so that the genset
can be operated. Storing the Genset
OPERATION
Storing the Genset: Proper storage is essential for
Connecting Shore Power preserving top genset performance and reliability
when the genset will be idle for more than 120 days.
If the boat has provisions for connecting shore pow-
er, it must also have an approved device to keep the 1. Change the engine oil (Page 3-4) and attach a
genset and shore power from being interconnected. tag indicating viscosity grade (Page 1-2).
2. Disconnect the battery cables (negative [−]
WARNING Backfeed to shore power can cause first) from the battery (Page 3-6). Follow the
electric shock resulting in severe personal inju- manufacturer’s recommendations when stor-
ry or death and damage to equipment. The boat ing the battery.
must have an approved device to prevent the
genset from being interconnected with shore
WARNING Hot coolant is under pressure
power.
and can cause severe burns when loosen-
New or Re-Built Engine Care ing the pressure cap. Let the engine cool
before loosening the pressure cap.
Change the oil and oil filter after the first 50 hours of
operation with a new or re-built engine (Page 3-4). 3. Check coolant level and add as necessary
(Page 3-7). Test the coolant mixture if freezing
No-Load Operation temperatures are possible and change if nec-
essary.
Keep no-load operation to a minimum. During
4. If freezing temperatures are expected, drain
no-load operation cylinder temperatures drop to the
the heat exchanger (Page 3-12), hoses and
point where fuel does not burn completely, causing
muffler to prevent damage from freezing water.
fuel wetting and white smoke. It is best to run the
genset at 1/4 to 3/4 load. 5. Clean and lightly oil parts that can rust.
Exercising the Genset
Returning the Genset to Service:
Exercise the genset at least 1 hour every month if 1. Check the oil tag on the genset and change the
use is infrequent. Run the genset at 1/4 to 3/4 load. oil (Page 3-4) if the viscosity is not appropriate
A single exercise period is better than several short- for the temperatures expected (Page 1-2).
er periods. Exercising a genset drives off moisture,
re-lubricates the engine, uses up fuel before it be- 2. Reconnect the battery cables (negative [−] last)
comes stale and removes oxides from electrical (Page 3-6).
contacts and generator slip rings. The result is bet-
3. Replace the raw water pump impeller if it was
ter starting, more reliable operation and longer en-
installed more than a year ago (Page 3-10).
gine life.
4. Perform the maintenance required (Page 3-1),
Cold Temperature Operation conduct the pre-start checks (Page 2-2) and
prime the fuel system (Page 2-2).
Do not let raw water freeze in the heat exchanger
(Page 3-12) during cold weather when the genset is 5. Start and run the genset (Page 2-2).
2-3
3. Periodic Maintenance
Periodic maintenance is essential for good perfor- ever, warranty work must be completed by an au-
mance and long genset life. Use Table 3-1 as a thorized Onan dealer.
guide for normal periodic maintenance.
WARNING Accidental or remote starting can
Maintenance, replacement or repair of emission cause severe personal injury or death. Discon-
control devices and systems may be performed by nect the negative (−) cable at the battery to pre-
any engine repair establishment or individual. How- vent starting while working on the genset.
TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY
Every P
After Every Every Every Every 5 years/ a
first Day/ Month/ Year/ Year/ Every Every 2000 g
PROCEDURE 50 Hrs 8 Hrs 100 Hrs 200 Hrs 500 Hrs 800 Hrs 2 years Hrs e
General Inspection1 x 3-2

Check Engine Oil Level x 3-3
Check Battery x2 3-6
Check V-Belt Tension x3 3-10
Drain Water in Fuel x 3-5
Check Siphon Break x 3-8
Change Oil & Oil Filter x x 3-4
Change Fuel Filter x 3-5
Replace Raw Water Impeller x 3-10
Adjust Valve Lash x5 −
Change Coolant, Pressure
x4 3-7
Cap & Thermostat
Check Generator Bearings,
Drive Belt, Belt Tensioner & x5 −
Drive Coupling
1 - Includes Oil Level, Coolant Level, Fuel System, Exhaust System and Battery Checks.
2 - See battery manufacturer’s recommendations.
3 − Check for slippage, cracking and wear (pump drive belt only).
4 − There is no zinc anode to replace.
5 - Must be performed by a trained and experienced mechanic (authorized Onan dealer) in accordance with the engine and genset Service
Manuals.
3-1
GENERAL INSPECTION Coolant Level Check
Inspect the genset before the first start of the day Keep the level of coolant in the recovery tank be-
and after every eight hours of operation. tween COLD and HOT. The recovery tank is de-
signed to maintain coolant level; not to fill the sys-
Oil Level tem. If the tank is empty, check for and repair any
coolant leaks and refill the system through the fill
neck on the engine (Filling the System, Page 3-8).
Check engine oil level (Page 3-3).
Then refill the recovery tank up to the COLD mark.
Use the recommended mixture of antifreeze
Exhaust System (Page 3-8).
Inspect the exhaust system for leaks and loose Raw Water System
hose clamps at the exhaust manifold, exhaust el-
bow, muffler, water separator and hull fittings. Re- Clean out the sea water strainer if necessary and
place damaged sections of exhaust hose. make sure the sea cock is open for genset opera-
tion. Also, when a water/exhaust separator is pro-
Check that all CO monitors are working properly. vided (see Installation Manual), open the sea cock
for the water drain hose.
WARNING EXHAUST GAS IS DEADLY! Do not Battery Connections
operate the genset until all exhaust leaks have
been repaired. Check the battery terminals and keep them clean
and tight (Page 3-6). Loose or corroded terminals
Fuel System have high electrical resistance, which can cause
hard starting and short starter life.
Check for leaks at hose, tube and pipe fittings in the
fuel supply and return systems while the genset is Mechanical
running and while it is stopped. Check flexible fuel
hose for cuts, cracks, abrasions and loose hose Look for mechanical damage. Start the genset and
clamps. Make sure fuel lines do not rub against oth- look and listen for any unusual noises and vibra-
er parts. Replace worn or damaged fuel line parts tions.
before leaks occur. Replace hose with with USCG
TYPE A1 or ISO 7840-A1 fuel hose. Check the genset mounting bolts to make sure they
are secure.
WARNING Fuel leaks can lead to fire. Repair Check to see that the genset air inlet and outlet
leaks immediately. Do not run the genset if it openings are not clogged with debris or blocked.
causes fuel to leak. Keep the genset and generator compartment clean.
Prime the fuel system (Page 2-2) if the genset ran Monitor the engine gauges, if so equipped, whenev-
out of fuel. er the genset is running.
3-2
CHECKING ENGINE OIL LEVEL
OIL FILL NECK WITH
PLUG AND
Shut off the genset before checking engine oil level. ATTACHED DIPSTICK
WARNING Crankcase pressure can blow hot

engine oil out the fill opening causing severe
burns. Always stop the genset before removing
the oil fill plug.
1. Pull the plug and dipstick out of the oil fill neck
(Figure 3-1). The plug may be difficult to pull
straight out. It is easier if you tilt the plug in its
socket while pulling out. Wipe off the dipstick
and thread it back into the fill neck and seat the
plug, which snaps into its socket. Remove the
plug and dipstick again and check the oil level
on the dip stick.
2. Add or drain oil as necessary. See ENGINE OIL

RECOMMENDATIONS (Page 1-2). Keep the
oil level between the high and low beads on the
end of the dipstick, as shown. It is not neces-
sary to add oil between oil changes if the oil has
KEEP OIL LEVEL
not dropped more than 1/3 of the way between BETWEEN THESE
the high and low beads. A full quart (0.9 liter) TWO BEADS ON
can be added if the oil level is at the lower bead. DIPSTICK
CAUTION Too much oil can cause high oil

consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the high and low beads on the dipstick.
3. Secure the oil fill plug, which snaps into its

socket. FIGURE 3-1. OIL FILL NECK AND DIPSTICK
3-3
CHANGING ENGINE OIL AND FILTER
WARNING U. S. state and federal agencies
have determined that contact with used engine
oil can cause cancer or reproductive toxicity.
Avoid skin contact and breathing of vapors. Use
rubber gloves and wash exposed skin.
See Table 3-1 for scheduled oil change.
1. Run the genset under load until it is up to oper-
ating temperature, stop it and disconnect the
negative (−) battery cable at the battery.
WARNING Accidental or remote starting
can cause severe personal injury or death.
Disconnect the negative (−) cable at the bat-
tery to prevent the engine from starting.
2. Remove the oil fill plug (Figure 3-1), open the
front access door and drain the engine oil into
a container by opening the drain valve (Fig-
ure 3-2). (The drain valve has a 3/8 NPT outlet
for connecting a hose fitting to facilitate oil
draining.) If an oil pump-out system is installed, OIL DRAIN OIL
VALVE FILTER
follow the instructions provided.
3. Close the oil drain valve.
4. Spin off the old oil filter (Figure 3-2) and wipe off FIGURE 3-2. OIL FILTER AND DRAIN VALVE
the filter mounting surface. (A filter wrench is
available from Onan.) Remove the old gasket
if it does not come off with the filter.
5. Apply a film of oil to the filter gasket and spin the
new filter on by hand until the gasket just
touches the mounting pad and tighten 3/4 turn.
6. Refill with 2.2 quarts (2.1 l) of oil. See ENGINE
OIL RECOMMENDATIONS (Page 1-2).
7. Start and run the genset for five minutes and
check for leaks. Stop the genset and check oil
level (Page 3-3). Add or drain oil as neces-
sary.
CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe
engine damage. Keep the oil level between
the high and low beads on the dipstick.
8. Close the access door and dispose of the used
oil and oil filter in accordance with local environ-
mental regulations.
3-4
DRAINING / CHANGING FUEL FILTER fuel quality is poor or condensation cannot be
avoided.
WARNING Diesel fuel is combustible and can 1. Disconnect the negative (−) cable at the battery
cause severe personal injury or death. Do not to prevent the engine from starting and close
smoke near fuel tanks or fuel-burning equip- the fuel supply valve, if provided, to prevent
ment or in areas sharing ventilation with such loss of prime.
electrical arcs and switches and all other 2. Open the front access door and drain the filter
sources of ignition well away. Keep a multi- (about 1/2 cup [120 ml]) into a suitable contain-
class ABC fire extinguisher handy. er by removing the drain plug (bottom of filter).
3. Re-install the drain plug, close the access door
Fuel Handling Precautions: Keep dirt, water and and dispose of the drain-off in accordance with
other contaminants from entering the fuel system local environmental regulations.
and corroding or clogging fuel injection compo-
nents. The genset has a water separator type of fuel Changing Fuel Filter: See Table 3-1 for scheduled
filter. The fuel supply system should also have a wa- change. Change the filter if the engine lacks power.
ter separator and filter. 1. Disconnect the negative (−) cable at the battery
to prevent the engine from starting and close
Humid air condenses on the walls of fuel tanks and the fuel supply valve, if provided, to prevent
is the primary source of water in fuel. Water clogs loss of prime.
fuel passages by freezing and causes corrosion by
forming sulfuric acid with the sulfur in the fuel. Keep- 2. Open the front access door and spin off the old
ing fuel tanks full reduces condensation by reducing filter (Figure 3-3) and dispose of it in accor-
the area on which condensation can take place. dance with local environmental regulations.
3. Clean the contact surface on the filter base, lu-
WARNING Accidental or remote starting can bricate the new filter gasket and spin the new
cause severe personal injury or death. Discon- filter on hand tight.
nect the negative (−) cable at the battery to pre-
vent the engine from starting. 4. Prime the engine for at least 30 seconds
(Page 2-2) to fill the new filter. Run the genset
Draining Water and Sediment: Drain water and and check for leaks. Tighten the filter by hand,
sediment more often than scheduled (Table 3-1) if if necessary, and close the access door.
FUEL
FILTER
FIGURE 3-3. FUEL FILTER
3-5
MAINTAINING BATTERY AND BATTERY
CONNECTIONS
WARNING Flames, sparks or arcing at battery
terminals, light switches or other equipment
can ignite battery gas causing severe personal
injury — Ventilate the battery area before work-
ing on or near the battery — Wear safety glasses
— Do not smoke — Switch a work lamp ON and
OFF away from the battery — Do not disconnect
the battery cables while the genset is running or
a battery charger is on — Always disconnect the
negative (−) cable first and reconnect it last.
See Table 3-1 for scheduled maintenance. Follow
the battery manufacturer’s instructions. Have the
battery charging system serviced if DC system volt-
age is consistently low or high. Always:
1. Keep the battery case, terminals and cables
clean and dry and the terminals tight at the bat-
tery and at the genset (Figure 3-4).
2. Remove battery cables with a battery terminal
puller.
3. Make sure which terminal is positive (+) and
which is negative (−) before making battery
connections. Always remove the negative (−)
cable first and reconnecting it last to reduce
arcing.
4. Follow the manufacturer’s recommendations
when storing the battery. Disconnect the bat- FIGURE 3-4. BATTERY CABLE TERMINALS
tery so that it does not discharge through the
genset control during storage.
3-6
ENGINE COOLING SYSTEM Replenishing Normal Coolant Loss
Keep the level of coolant in the recovery tank be-
Cooling System Overview tween COLD and HOT. The recovery tank is de-
signed to maintain coolant level; not to fill the sys-
Refer to Figure 3-5. The engine is cooled by a pres- tem. If the tank is empty, check for and repair any
surized, closed-loop liquid cooling system. Coolant coolant leaks and refill the system through the fill
is pumped through passages in the engine block, neck on the engine (Filling the System, Page 3-8).
head and exhaust manifold. The exhaust manifold Then refill the recovery tank up to the COLD mark.
also serves as the engine coolant reservoir. Use the recommended mixture of antifreeze
(Page 3-8).
The heat exchanger is mounted inside the exhaust
manifold. Raw water (the flotation water) is pumped Make sure the two hoses from the recovery tank are
through tubes in the heat exchanger to cool the en- routed through the two holes in the right side of the
gine coolant. The raw water then passes through a genset enclosure, that the coolant recovery hose is
hose into the exhaust-water mixer where it cools the connected to the fill neck on the engine and that the
exhaust gases and is expelled. The V-belt drives the overflow hose terminates in the drip pan where it will
coolant and the raw water pumps. not splash coolant on electrical components.
HEAT RAW WATER FLOW PRESSURE CAP & HOSE BARB TO CONNECT EXHAUST
EXCHANGER SENSOR COOLANT FILL COOLANT RECOVERY MANIFOLD &
CLEANOUT NECK TANK COOLANT
COVER RESERVOIR
THERMOSTAT
HOUSING COULD BE
CONNECTED TO
EXTERNAL
SIPHON BREAK AT
THIS POINT—SEE
COOLANT INSTALLATION
PUMP MANUAL
BLOCK EXHAUST-WATER
DRAIN CAP MIXER WITH HIGH
TEMPERATURE
EXHAUST SWITCH
EXHAUST &
RAW WATER
RAW WATER OUT
PUMP
COOLANT
RAW WATER RAW WATER IN
FIGURE 3-5. ENGINE COOLING SYSTEM
3-7
Recommended Coolant Mixture Coolant Hoses: Inspect and replace hoses that
leak or are damaged.
Use the best quality ethylene or propylene glycol
antifreeze solution available. It should be fully for- Pressure Cap: See Table 3-1 for scheduled re-
mulated with rust inhibitors and coolant stabilizers. placement. The pressure cap is necessary for opti-
Use fresh water that is low in minerals and corrosive mal engine cooling and reduced coolant loss.
chemicals. Distilled water is best. Unless prohibited
by shipping regulations, the genset is shipped with Cleaning and Flushing the System: Use radiator
the recommended 50/50 mixture of water and ethyl- cleaning chemicals to clean and flush the cooling
ene glycol, which is good for -34° F (-37° C). Cool- system before refilling with fresh coolant. Follow the
ant capacity is 2.2 quarts (2.1 liters). cleaner manufacturer’s instructions.
WARNING Ethylene glycol antifreeze is con-
sidered toxic. Dispose of it according to local CAUTION Filling a hot engine with cold water
regulations for hazardous substances. can cause cracks in the manifold, head and
block. Follow the manufacturer’s instructions
Changing Coolant for cleaning and flushing.
See Table 3-1 for scheduled change of coolant. Filling the System: Secure the block drain cap and
reconnect the pump inlet hose and fill the system
Draining the System: Have towels and containers through the engine fill neck. The system will fill only
ready to wipe up, collect and properly dispose of the as fast as the air can escape. Fill to the bottom of the
coolant. fill neck. Start and run the engine for a couple of min-
utes to dislodge air pockets and shut it down. Add as
WARNING Accidental or remote starting can much coolant as necessary and secure the pres-
cause severe personal injury or death. Discon- sure cap. Then refill the recovery tank up to the
nect the negative (−) cable from the battery to COLD mark.
prevent the engine from starting.
WARNING Hot coolant is under pressure and CAUTION Low coolant level can cause severe
can cause severe burns when loosening the engine damage. Make sure the system is full.
pressure cap. Let the engine cool before loos-
ening the pressure cap. Siphon Break
1. Disconnect the negative (−) cable at the battery
to prevent the engine from starting, let the en- A siphon break is installed when the exhaust-water
gine cool and remove the front and top access mixer (Figure 3-5) is below the water line. If of a
doors and the coolant pressure cap. spring-loaded valve design, check for free move-
ment of the plunger. Replace the device if the plung-
2. Drain the exhaust manifold/coolant reservoir er does not move freely or the body is encrusted
by disconnecting the hose at the coolant pump with deposits from leakage past the valve seat. If of
inlet (Figure 3-5) and twisting it down into a the bleed-vent type, check that the vent hose is
container. properly connected on both ends. If the vent is con-
3. Drain the block by removing the cap on the nected to a through-hull fitting, check for normal wa-
drain fitting on the left side of the block (Fig- ter flow whenever the engine is running. See the
ure 3-5). Use an 11/16 inch socket on a swivel Installation Manual for more information regarding
and 12 to 18 inch extension. To catch the cool- siphon breaks.
ant and direct it into a container, insert the sock-
et and extension through a piece of hose large WARNING Bypassing a siphon break or failing
enough to fit over the socket but shorter than to maintain it can lead to engine flooding and
the extension. The hose will catch the coolant damage to the engine not covered under War-
as the cap is being unscrewed. ranty.
3-8
Replacing the Thermostat
cause severe personal injury or death. Discon-
vent the engine from starting.
WARNING Hot coolant is under pressure and

can cause severe burns when loosening the
pressure cap. Let the engine cool before loos-
ening the pressure cap.
See Table 3-1 for scheduled replacement. Refer-

ring to Figure 3-6, replace the thermostat as follows:
to prevent the engine from starting, let the en-
gine cool and remove the top access door and THERMOSTAT
pressure cap.
2. Pack a towel around the thermostat housing
flange to catch the coolant that will spill. Re-
move the two thermostat housing bolts and pull
off the housing, thermostat and gasket. The
hose does not need to come off.
3. Clean off the gasket area and install the new FIGURE 3-6. THERMOSTAT
thermostat and gasket. Apply Three Bond 1215
liquid sealant or equivalent to the top side of the
gasket.
4. Replenish any lost coolant, secure the pres-
sure cap, secure the access door and recon-
nect the battery cables (negative [−] last).
3-9
Adjusting V-Belt Tension
TENSION 3/8 INCH DRIVE SOCKET
ADJUSTING USE TO TENSION BELT
Referring to Figures 3-7 and 3-8, readjust belt ten- BOLT
sion as follows:

to prevent the engine from starting.
2. Remove the front and top access doors. If work
space is limited, remove the side panel (Fig-
ure 3-8) to be able to hold the nut on the pump
pivot bolt (Figure 3-7) with an open-end wrench PUMP
while loosening the bolt. PIVOT
BOLT
3. Loosen both bolts so that the pump can pivot.
4. Pivot the pump out to tighten belt tension. Hold
tension by tightening the tension adjusting bolt
and check it by applying 20 pounds (10 kg) to
the middle of the pulley span. Belt tension is
correct when deflection is 0.4 inch (10 mm). PUMP PIVOT BOLT,
5. Tighten the bolts, reassemble the panels and SPACER, WASHER,
LOCKWASHER & NUT
doors and reconnect the battery cables (nega-
tive [−] last).
FIGURE 3-7. ADJUSTING V-BELT TENSION
Replacing the Raw Water Pump Impeller
REMOVE THESE
7 SCREWS
See Table 3-1 for scheduled replacement. Have
towels and containers ready and avoid spilling raw
water on the electrical components below the pump.
Referring to Figures 3-8, 3-9 and 3-10, replace the
impeller as follows:

to prevent the engine from starting, let the en-
gine cool and close the sea cock.
2. Remove the front and top access doors. If work
space is limited, remove the side panel (Fig-
REMOVE THESE
ure 3-8) to be able to hold the nut on the pump
DOORS & PANELS
pivot bolt (Figure 3-9) with an open-end wrench
while loosening the bolt. FIGURE 3-8. REMOVING ACCESS PANELS
3-10
3. Loosen the hose clamps shown in Figure 3-9
and disconnect the hoses. TENSION LOOSEN THESE
ADJUSTING 2 HOSE CLAMPS
4. Loosen the two pump mounting bolts and re- BOLT
move the belt. Remove the tension adjusting
bolt first and swing the pump out for access to
the pivot bolt nut, lock washer and flat washer.
Remove the pivot bolt and pull the pump out.
5. Remove the 4 pump cover screws (Fig-

ure 3-10) and remove the impeller and O-ring.
Use two pliers to grip vanes on opposite sides
if the impeller is difficult to remove. It will be nec-
essary to check for and cleanout pieces of the
impeller from the heat exchanger and exhaust
elbow if vanes have broken off.
PUMP
PIVOT
6. Install the new impeller. It helps to twist the im- BOLT
peller counter-clockwise (the way it turns) while
squeezing it into the housing.
PUMP PIVOT BOLT,
7. To provide initial lubrication and better pump SPACER, WASHER,
LOCKWASHER & NUT
suction before water reaches the pump, wet the
inside of the pump and impeller with water,
soap solution or a silicone lubricant and secure
FIGURE 3-9. REMOVING RAW WATER PUMP
the O-ring and cover.
CAUTION Do not lubricate with petroleum

products like grease and oil which chemi-
cally attack impeller materials.
O-RING
8. Remount the pump, reconnect the hoses, ad-

just V-belt tension (Page 3-10) and reassemble
the enclosure panels and doors.
9. If the sea water strainer is above the water line,

fill it for faster prime and secure its cover.
10. Open the sea cock, reconnect the battery IMPELLER

cables (negative [−] last) and start the genset.
The genset will shut down within 8 seconds if
there is no raw water flow and the amber status COVER AND
SCREWS
lamp will blink shutdown Code No. 7
(Page 9-6). If it shuts down, find out why, re-
move any blockage and restart the genset. FIGURE 3-10. REPLACING THE IMPELLER
3-11
Heat Exchanger
The heat exchanger has a cleanout cover and drain FLOW SENSOR MOUNTING BOLT
plug (Figure 3-11). Clean the raw water tubes if the (1 OF 4)
engine keeps shutting down (Code No. 1) or the en-
gine gauge indicates abnormally high engine tem-
peratures. Drain the heat exchanger if there is a
danger of freezing when the genset is not running or
is in storage. (Freezing water can damage the raw
water tubes in the heat exchanger. Engine coolant,
but not raw water, is protected from freezing.)
Cleaning and Draining the Heat Exchanger: To

clean the tubes or to drain raw water, first remove
the side enclosure panel or the raw water pump (see
Replacing the Raw Water Pump Impeller,
Page 3-10). Have towels and containers ready to
prevent spilling raw water on the electrical compo-
nents below the heat exchanger.
CLEANOUT DRAIN PLUG
Remove the drain plug or cleanout cover. Clean and COVER
flush the tubes. The drain plug must be removed to
get all the water out of the tubes. Do not use metal
rods to clean the tubes. The tubes are made of rela-
tively soft copper alloy and can be damaged.
Use thread sealant on the drain plug and a new

clean out cover gasket if the old one is torn or other-
wise damaged. Reassemble all the parts that were
disassembled for access.
Removing/Installing the Heat Exchanger: Re-

move the heat exchanger and have it cleaned at a
radiator shop if there is hard scale in the tubes.
To remove the heat exchanger, first disconnect the

two leads at the flow sensor, remove the sensor,
drain the coolant and disconnect the three hoses.
(To work the coolant hose elbow off the fitting on the
heat exchanger, it will be necessary to loosen the
hose clamps on both ends.) Then remove the four
mounting bolts and withdraw the heat exchanger.
FIGURE 3-11. HEAT EXCHANGER
To install the heat exchanger, first clean the mating

gasket faces, taking special care not to scratch the
face on the aluminum manifold. Use a new gasket
and torque the mounting bolts to 19 lb-ft (26 N-m).
Then install the flow sensor using pipe thread seal-
ant and reconnect the two leads in the harness. Re-
connect the hoses and reassemble all the parts that
were disassembled for access.
3-12
4. Enclosure, Drip Pan and Mounting System
ENCLOSURE PANELS Back Panel: This panel is secured by 5 screws
along its left edge (looking from the back), 3 along
The genset enclosure panels and access doors are its right edge and 7 on its back. Remove this panel
assembled as shown (Figure 4-1). for access to the generator drive (Page 7-1).
WARNING Accidental or remote starting can Right Side Panels: The main panel is secured by
cause severe personal injury or death. Before 5 screws, 1 near each corner and 1 near the center.
removing a panel or access door, disconnect The smaller panel is secured by 3 screws. Remov-
the negative (−) cable at the battery to prevent ing these panels provides access to the engine
the engine from starting. components on the right side (Page 3-7).
RIGHT SIDE TOP DOOR FRONT STANDOFF OUTPUT GENSET

PANELS ACCESS LINTEL ACCESS INSULATOR BOX COVER GROUNDING
DOOR DOOR SCREW
ASSEMBLY
FRONT / LEFT
BACK AIR INTAKE AC OUTPUT GENERATOR SIDE PANEL LEFT ACCESS
PANEL DUCT BOX GROUNDING STRAP ASSEMBLY PANEL
FIGURE 4-1. GENSET ENCLOSURE
4-1
Access Doors: The access doors are latched and grounding screw and standoff insulator are for gen-
the front is lockable with a key. The door lintel be- erator, load and grounding connections (Page 6-6).
tween them is a channel secured by 1 screw on the
right side and 2 screws on the left. Air Intake Duct: The duct is secured to the back by
5 screws and to the side by 3 screws.
Front / Left Side Panel Assembly: This panel as-
sembly is secured by 2 screws to the access door DRIP PAN AND MOUNTING SYSTEM
lintel, 4 to the drip pan, 6 on the side and 1 in back
along the top edge, right of the AC outlet box. Re- Front Engine Support Bracket: Torque the 3 bolts
move this assembly and the access doors for full ac- that secure the bracket to the engine to 41 lb-ft
cess from the top, front and left side. To remove it, (55 N-m).
remove the 4 screws that secure the AC output box,
disconnect all wiring at the control panel and re- Vibration Isolation Mounts (3): Two of the three
move the two screws that secure the oil fill neck to mounts are bolted to the engine-generator adapter
the control panel (Page 8-5). This panel assembly (Page 7-1) and one to the front mount. Torque the
can be pulled forward and removed without having through bolts and the two mounting bolts to the drip
to disturb connections in the AC output box. pan to 20 lb-ft (27 N-m).
AC Output Box: The AC output box is secured by Generator End Bell Support Bracket: See
4 screws in the bottom of the box. The genset Page 6-1. Torque all the bolts to 8 lb-ft (11 N-m).
FRONT ENGINE
SUPPORT BRACKET
VIBRATION
ISOLATION
MOUNT (3)
GENERATOR END
BELL SUPPORT
BRACKET
DRIP RUBBER NOISE

PAN PLUGS
FIGURE 4-2. DRIP PAN AND MOUNTING SYSTEM
4-2
5. Control System
OVERVIEW functions required to operate the genset. All con-

nections to the controller are through connectors
Controller A1 is an integrated microcontroller- P1 (black), P2 (grey) and P3 (green). Refer to the
based engine and generator control (Figure 5-1). It wiring diagrams and wiring harness drawings on
provides all the control, monitoring and diagnostic Pages A-1 and A-2.
GLOW PLUG 2-POLE CIRCUIT CONTROL

RELAY BREAKER SWITCH
K3 CB3 S4
CONTROLLER
A1
CONNECTORS EMERGENCY
P1, P2 & P3 SWITCH/BREAKER
CB1
BATTERY CHARGING
REGULATOR ASSEMBLY HOUR
AVR1 WITH HEAT SINK METER
M11
FIGURE 5-1. CONTROL SYSTEM COMPONENTS
5-1
CONTROLLER A1 Stop: Touch the control switch to STOP (Prime).
The controller:
Major Functions 1. Disables output voltage.
Figure 5-2 is a block diagram of controller functions. 2. Deenergizes the fuel lift pump and governor ac-
tuator.
Initialization: Control initialization consists of 3. Turns off the green run lamp.
checking memory (RAM, ROM, EEPROM) and
genset configuration. 4. Writes session data (number of cranks, min-
utes of operation, last fault, etc.) to non-volatile
Fuel Prime: Press and hold the control switch at memory (NVM).
STOP (Prime) for more than 3 seconds to cause 5. Removes processor power when idle 5 min-
fuel pump E5 to prime the fuel system. utes.
Startup: Press and hold the control switch at Note: Stop takes precedence over Start if both pres-
START (Preheat) until the genset starts. The con- ent due to a faulty switch or other cause.
troller:
Voltage Control: The controller maintains nominal
1. Energizes fuel lift pump E5. AC output voltage during steady state operation by
2. Energizes the glow plugs (two) during pre-heat varying field current as load varies. In response to
and cranking. The duration of pre-heat prior to transient loads it lowers the voltage setpoint to allow
cranking is engine temperature dependent, but engine recovery. Field power (DC) is supplied by the
does not exceed 15 seconds. quadrature windings (AC) through the controller.
3. Enables the amber status lamp to blink rapidly. Fuel Control: The controller maintains nominal fre-
4. Enables some fault detection. quency as load varies by modulating the pulse width
of the current energizing governor actuator A12,
5. Enables cranking. The maximum allowed dura- which moves the fuel rack.
tion of cranking is engine temperature depen-
dent and varies between 20 and 60 seconds. Voltage Control: The controller maintains nominal
AC output voltage during steady state operation by
6. Enables field flash (F1-F2).
modulating field current as load varies. In response
7. Energizes governor actuator A12 (full rack). to transient loads it lowers the voltage setpoint to al-
8. Disconnects the starter (B1) at 800 rpm. low engine recovery. Field power (DC) is supplied
by the quadrature windings (AC) through the con-
9. When operating speed is reached: troller.
A. Enables output voltage.
Voltage Adjustments: See ADJUSTING VOLT-
B. Turns off field flash. AGE (Page 6-5).
C. Turns off amber status lamp.
Frequency Adjustments: See ADJUSTING FRE-
D. Turns on green run lamp. QUENCY (Page 6-5).
E. Enables Switched B+ (J7). Fault Monitoring, Shutdown and Diagnostics:
F. Enables complete fault detection. See Troubleshooting (Page 9-1).
5-2
COOLANT TEMPERATURE SENDER
LOCAL
CONTROL
OIL PRESSURE SENDER
RAW WATER PRESSURE SWITCH
REMOTE EXHAUST TEMPERATURE SWITCH

CONTROL
ENGINE
FUEL LIFT PUMP
STARTER
RS-232
(FACTORY ONLY)
GLOW PLUGS
CONTROLLER
GOVERNOR ACTUATOR
REMOTE ENGINE
GAUGES
QUADRATURE
EMERGENCY
SYSTEM FIELD
GENERATOR
AC SENSE
BATTERY
BATTERY CHARGING
AC OUTPUT
FIGURE 5-2. CONTROLLER A1 BLOCK DIAGRAM
5-3
Controller Removal / Replacement
AMBER
cause severe personal injury or death. Before
removing a panel or access door, disconnect GREEN
the negative (−) cable at the battery to prevent
the engine from starting.
The controller is mounted in the second intake reso-
nator chamber where it is cooled by the intake air
and is accessible through the left access panel (Fig- SCHEMATIC
ure 5-1). It is easier to remove if all the screws se-
curing the front / left side panel are loosened from THIS SIDE UP
the drip pan and other panels so that the panel can
be shifted. Alternatively, remove the AC output box
(Page 4-1).
When removing a connector plug from the control-
TERMINALS
ler, squeeze the locking tabs on the sides while pull-
ing out. When reinstalling a plug, make sure the seal
is in place and that the locking tabs snap into posi- FIGURE 5-3. CONTROL SWITCH S4
tion.
Make sure to properly reconnect the generator
grounding strap (Page 4-1), leads and load wiring
(Page 6-6), if they have been disconnected.
CONTROL SWITCH S4
The switch is mounted on the control panel (Fig-
ure 5-1). Unsnap the connector for access to its ter-
minals. Replace the switch if Start does not close
terminals 2 and 3, Stop does not close terminals 1
and 2, Green does not light when 12 VDC is applied
across terminals 7 (−) and 8 (+), or Amber when
12 VDC is applied to terminals 7 (−) and 6 (+).
Note: The switch snaps in either way on the con-
trol panel. The row with 2 terminals must be up,
otherwise Start and Stop will be reversed.
EMERGENCY SWITCH/BREAKER CB1
The switch/circuit breaker is mounted on the control
panel (Figure 5-1). Disconnect the leads and check
electrical continuity across the two terminals. Re-
place the circuit breaker if it does not reset or turn
ON and OFF.
HOUR METER M11
The hour meter is mounted on the control panel
(Figure 5-1).
5-4
LINE CIRCUIT BREAKER CB3
removing a panel or access door, disconnect
the negative (−) cable at the battery to prevent COOLANT
the engine from starting. TEMPERATURE
SENDER E2
The line circuit breaker is mounted in the AC output
box as shown (Figure 5-1). Disconnect all leads and
check electrical continuity across each pole. Re-
place the circuit breaker if either pole does not reset
or turn ON and OFF. Reconnect the generator and
load wires properly (Page 6-6).
ENGINE OIL PRESSURE SENDER E1

The oil pressure sender is threaded into the side of
the block with pipe fittings (Figure 5-4) and is acces-
sible by removing the right side panel or the raw wa-
ter pump (Page 3-10). Use thread sealant and en-
gage at least two full threads when installing. In
isolated-ground applications the sender has two ter-
minals.
Replace the sender if resistance is not between

227 and 257 ohms when the engine is idle (0 psi),
or is not reasonably steady between 50 and 200
ohms when the engine is running and known to
have normal oil pressure.
OIL
ENGINE COOLANT TEMPERATURE PRESSURE
SENDER E2 SENDER
E1
The engine coolant temperature sender is threaded
into the top of the head (Figure 5-4) and is accessi-
FIGURE 5-4. OIL AND TEMPERATURE SENDERS
ble through the top access opening. Use thread
sealant and engage at least two full threads when
installing. In isolated-ground applications the send-
er has two terminals.
Replace the sender if resistance is not approximate-

ly 800 ohms at room temperature or does not de-
crease rapidly when immersed in boiling water.
5-5
RAW WATER FLOW SWITCH S6

The raw water flow switch is threaded into the heat

exchanger (Figure 5-5) and is accessible through
the top access opening. Use thread sealant and en- RAW WATER
gage at least two full threads when installing. FLOW
SWITCH S6
Check continuity across the switch terminals while
blowing into it (1 psi). Replace the switch if it does
not open and close.
HIGH EXHAUST TEMPERATURE SWITCH

S5
The high exhaust temperature switch is bolted to the

ear on the side of the water/exhaust mixer (Fig-
ure 5-5). The switch is accessible by removing the
enclosure back panel.
GLOW PLUG RELAY K3
The glow plug relay is mounted on its wiring socket

(Figure 5-1). Pull the relay out to test it. Apply
12 VDC across terminals 85−86. Replace the relay
if the contacts across terminals 30−87 (NO) do not
open and close.
BATTERY CHARGING REGULATOR AVR1

HIGH EXHAUST
Mounting: The regulator and heat sink are TEMPERATURE
mounted on the air intake duct (Figure 5-1). The SWITCH S5
regulator is easier to remove if the AC outlet box is
tilted out (secured by 4 screws inside the box).
Testing: See Page 6-4 to test battery charge wind-

ing B1−B2. To test the regulator, remove the lead
from terminal B+. If B1−B2 output is 15 to 20 VAC,
but regulator output is less than 12.8 VDC, replace FIGURE 5-5.RAW WATER FLOW AND HIGH EX-
regulator AVR1. HAUST TEMPERATURE SWITCHES
GROUND ISOLATION RELAY K9
See starter service (Page 8-9).
5-6
6. Generator
OVERVIEW the rotor windings through the brush block assem-
bly. The rotor shaft is supported on both ends by
These are 2-bearing, belt-driven, 2-pole revolving- sealed ball bearings. The drive belt pulley and fan
field generators with brushes and slip rings (Fig- are center-bolted to the tapered rotor ends.
ure 6-1). Output voltage is regulated by microcon-
troller-based genset controller A1 (Page 5-1). Brush Block: Field current passes through the
brush block which has two spring-loaded carbon
Stator: The stator consists of steel laminations with brushes that make contact with the rotor slip rings.
three sets of windings in the lamination slots. The
main windings (T1−T2, T3−T4) are for powering the Principle of Operation: During startup genset con-
connected loads, the quadrature winding (Q1−Q2) troller A1 flashes the field with battery current for
is for field excitation and the (B1−B2) winding for fast buildup of generator voltage as the engine ac-
battery charging. celerates to operating speed. During operation, the
controller maintains nominal AC output voltage by
Rotor: The rotor consists of a shaft with steel lami- varying field current in response to load. In re-
nations wrapped with field windings. A molded slip sponse to transient loads, the controller lowers the
ring assembly is pressed on to supply field current to voltage setpoint to allow for engine recovery.
END BELL BRUSH BLOCK

SUPPORT BRACKET ASSEMBLY
END BELL
WAVE WASHER
O-RING
SLIP
RINGS
ROTOR
FAN
STATOR
O-RING THROUGH
BOLTS (4)
LEADS,
GROMMET
& CLIP
Note: On skewed stators, (Straight Stator Shown) the throughbolts must

ENGINE-GENERATOR come through the slotted rather than round holes for proper alignment of
ADAPTER end bell, stator and adapter.
FIGURE 6-1. GENERATOR
6-1
SERVICING THE GENERATOR Stator Reassembly
Reassembly is the reverse of removal. Note the fol-

WARNING Accidental or remote starting can lowing:
removing a panel or access door, disconnect 1. Loosen the end bell support bracket bolts, if not
the negative (−) cable at the battery to prevent already removed, so that the bracket does not
the engine from starting. interfere with proper stator and end bell align-
ment.
Stator Removal 2. Align the stator and end bell with the line
scribed on them during disassembly.
1. Disconnect the generator leads inside the AC
outlet box and remove the top, front and left Note: Figure 6-1 shows a straight stator and the
side access doors and panels (Page 4-1). through bolts lined up to pass through round
holes in the stator laminations. On models with
2. Remove the second intake resonator chamber skewed stators the through bolts must pass
(Page 8-2). through slotted holes for the end bell, stator and
adapter to line up properly.
3. Remove the brush block (Figure 6-1). 3. Relubricate the bearing bore in the end bell with
molybdenum disulfide paste (Onan
CAUTION The brushes can be damaged if
PN 524-0118 or equivalent).
the brush block is not removed before re-
moving the end bell. 4. Make sure the wave washer and O-ring are in
place in the bearing bore.
4. Remove the fan hub bolt and fan. (To keep the
5. Torque the stator through bolts and end bell
rotor from turning while loosening the fan bolt,
bracket bolts to 8 lb-ft (11 N-m) and the fan hub
hold the pulley bolt with a wrench.) To pull the
bolt to 45 lb-ft (61 N-m). (To keep the rotor from
fan off the shaft taper, secure a three-point
turning while tightening the fan bolt, hold the
wheel puller to the three holes in the fan hub
pulley bolt with a wrench.)
with M6 or 1/4 inch self-tapping screws.
6. Make sure to tie the generator leads to the clip
5. Remove the end bell support bracket from the on the side of the generator.
engine bracket and the end bell (4 bolts).
6. Free the 8 generator leads from their connec- Rotor

tions and the clip on the side of the generator.
To remove the rotor, remove the stator and then the
7. Scribe a line across the adapter, stator lamina- drive pulley (Page 7-2) and pull the rotor straight out
tions and end bell to make realignment easier to the front. When reassembling, lubricate the bear-
during reassembly. ing bores in the end bell and adapter with molybde-
num disulfide paste (Onan PN 524-0118 or equiva-
8. Block the stator so that it does not fall against lent). Make sure the wave washer is in place in the
the rotor, and then remove the four generator end bell and that the O−rings are in place in the
through bolts. bearing bore groves in both ends.
9. Pull the generator end bell straight out. Ex- Use an adhesive when installing new bearings on
amine the bearing bore and replace the end bell the rotor shaft. Apply the adhesive to the shaft
if it is scored or otherwise damaged by the bear- (Locktite 680 or equivalent) and primer (activator) to
ing. the bearing (Locktite 747 or equivalent). Press each
10. Pull the stator assembly straight out, taking bearing on up to its shaft shoulder using a bench
care not to damage rotor or stator windings. press.
11. Block the rotor to support its hanging weight to CAUTION Apply force only to the bearing in-
prevent damage to the adapter and bearing. ner race to avoid damage to the bearing.
6-2
SERVICING BRUSHES AND SLIP RINGS
Brush Block
Access: For access to the brush block, remove the
enclosure front / left side assembly (Page 4-1) or
swing it out to the left. Move the second resonator
chamber (Page 8-2) out of the way by removing the
F−
bolt that secures it to the generator and by loosening F+
the clamp at the intake manifold.
Service: Disconnect the field leads from the brush
block (Figure 6-2), remove the mounting screw and FIGURE 6-2. BRUSH BLOCK
withdraw the brush block from the generator end
bell. Replace the brush block assembly if either
brush is shorter than 7/16 inch (11 mm), binds in the
brush block or is damaged in any way.
Reconnect the field leads, F− (black) to the outside
terminal, and F+ (red) to the inside terminal.
Slip Rings
Remove the brush block and inspect the slip rings
for grooves, pits, or other damage. Use a Scotch
Brite pad or commutator stone to remove light wear
or corrosion.
TESTING FIELD FLASH
Field flash can be tested by measuring output volt-
age while cranking with the governor actuator leads
(Page 8-6) disconnected to keep the engine from
starting. If output voltage increases at least 1 volt
while cranking, the whole field excitation system—
controller, brushes, slip rings and rotor—are prob-
ably in working order and the problem lies else-
where. See Troubleshooting (Page 9-1).
6-3
TESTING GENERATOR WINDINGS TABLE 6-1. GENERATOR WINDING RESISTANCES
RESISTANCE (OHMS)
WINDING
Testing the Rotor @ 77° F (25° C) ± 10%
T1−T2, T3−4 0.353
Field Resistance Test: Disconnect field leads F1 Q1−Q2 2.93
and F2 from controller A1 by pulling green connec- B1−B2 0.114
tor P3 and measure resistance across pins 7 and 8.
F1−F2 32
If resistance is not as specified in Table 6-1:
1. Check for and repair faulty field leads.
2. Service brush block and slip rings (Page 6-3).
3. Check rotor resistance across the slip rings
(Figure 6-3). Replace the rotor if resistance is
not as specified.
Ground Test: Using a megger or the highest scale

on a digital ohmmeter, measure resistance between
the rotor and either slip ring (Figure 6-4). Replace
the rotor if its winding has less than one megohm re-
sistance to ground.
Break-Out Tool 420−0624

Break-out tool 420−0624 for use in conjunction with
an accurate digital multi-meter is available for pre-
forming stator winding output tests while running the
generator set. The tool is plugged into the generator
set wiring harness in place of the generator set con-
trol. Follow the tool instructions.
FIGURE 6-3. OPEN OR SHORTED ROTOR TEST
2.Testing the Stator
Disconnect T1, T2, T3 and T4 from the terminals in
the output box. Disconnect B1 and B2 from charging
regulator AVR1 (Page 5-1). Disconnect Q1 and Q2
from controller A1 by pulling green connector P3
(Pins 4 and 5).
Open Winding Test: Measure resistance across

each winding lead pair (Table 6-1). Replace the sta-
tor if any winding is open (zero ohms).
Winding Resistance Test: Use a meter (Wheat-

stone Bridge) having 0.001 ohm precision to mea-
sure resistance across each winding lead pair
(Table 6-1). Replace the stator if resistance in any
winding is not as specified.
Ground Test: Using a megger or the highest scale

on a digital ohmmeter, measure resistance between
the stack and each stator lead. Replace the stator if
any winding has less than one megohm resistance
to ground.
FIGURE 6-4. GROUNDED ROTOR TEST
6-4
RECONNECTING THE GENERATOR To adjust voltage:
Reconnect the generator properly for the applica- 1. Disconnect all generator loads and connect ac-
tion. See Page 6-6. curate meters to measure AC volts and fre-
quency.
ADJUSTING FREQUENCY
WARNING HAZARDOUS VOLTAGE!
If it is necessary to change the output frequency for Touching uninsulated live parts inside the
the application, remove the access cover on the left genset or connected equipment can result
end of the genset. Find the leads marked J8 HZ, in severe personal injury or death. For your
60 HZ and 50 HZ in the wiring harness (Page A-2). protection, stand on a dry wooden platform
Connect 60 HZ or 50 HZ to J8 HZ, as appropriate, or rubber insulating mat, make sure your
and secure the access cover (4 screws). clothing and shoes are dry, remove jewelry
from your hands and use tools with insu-
ADJUSTING VOLTAGE lated handles.
Output voltage may need to be readjusted for the
2. Start the genset and let voltage and frequency
application, especially if it was necessary to change
stabilize for 5 to 10 seconds.
the frequency and/or reconnect the generator
(Page 6-6). Recheck generator reconnections 3. Rapidly press the control switch to START
and reconsider whether frequency needs to be 6 times within 10 seconds.
changed before attempting voltage adjustments.
Voltage is adjusted by means of the control switch. 4. To adjust voltage up, press the control switch
Rapidly pressing the switch to START 6 times dur- to START and release quickly. Each time the
ing the first minute after startup puts the genset con- switch is released, voltage will rise approxi-
troller into voltage set mode. The amber status indi- mately 0.6 volt.
cator lamp will begin blinking once every second to
5. To adjust voltage down, press the control
confirm voltage set mode. The green status indica-
switch to START and release in 1 second.
tor lamp will remain on. The controller resumes nor-
Each time the switch is released, voltage will
mal operating mode 20 seconds after the last ad-
drop approximately 0.6 volt.
justment.
Note: If a fault shutdown occurs or the control switch 6. Normal operation will resume in 20 seconds af-
is pressed to STOP during voltage set mode, voltage ter the last adjustment. The last adjustment will
adjustments will not be stored in controller memory. be retained by the controller.
6-5
100, 120 Volts 60 Hz 200, 240 Volts 60 Hz 100/200, 120/240 Volts 60 Hz
110, 115 Volts 50 Hz 220, 230 Volts 50 Hz 110/220, 115/230 Volts 50 Hz
A B C
GND GND
CB1 CB1 CB1
* * *
T1 T2 T1 T2
T1 T2
A − Jumper the two load terminals of the circuit breaker so that there is no imbalance of loads be-
tween the generator windings and both windings are available for large motor and air conditioner
starting. Bolt T2/T2/T4/L0/GND to the grounding stud in the outlet box.
B − Bolt T2/T2/T3 to the isolated terminal on the red standoff block in the outlet box. Bolt L0/T4 to
the grounding stud in the outlet box. Generator grounding must be in accordance with codes.
C − Bolt T2/T2/T3/L0(N)/GND to the grounding stud in the control box unless codes require an iso-
lated neutral (N).
Note: Always bolt the T1 voltage sense lead with the T1 winding lead and the T2 voltage
sense lead with the T2 winding lead.
* − Isolated terminal on red standoff block.
FIGURE 6-5. GENERATOR RECONNECTIONS
6-6
7. Generator Drive
OVERVIEW ible coupling. The generator pulley is center-bolted
to the tapered end of the rotor shaft. The pulley must
The engine drives the generator by means of a 6-rib
be removed to remove the generator rotor from the
“Poly-Vee” belt (Figure 7-1). The drive pulley is
engine-generator adapter.
mounted on the engine flywheel by means of a flex-
ENGINE
CRANKSHAFT
ENGINE-GENERATOR
ADAPTER
ENGINE FLYWHEEL
GENERATOR
ROTOR
FLEXIBLE COUPLING
AND HUB
GENERATOR
INLET AIR
DRIVE DUCT
PULLEY
GENERATOR
PULLEY
BELT
TENSIONER
ASSEMBLY
DRIVE BELT
FIGURE 7-1. GENERATOR DRIVE
7-1
INSPECTING DRIVE AND BEARINGS with a wrench.) Torque the center bolt to 45 lb-ft
(60 N-m) when reassembling. Make sure to install
WARNING Accidental or remote starting can the generator inlet air duct before installing the
cause severe personal injury or death. Before pulley.
the negative (−) cable at the battery to prevent Generator Inlet Air Duct
Torque the three mounting bolts to 8 lb-ft (12 N-m).
Remove the back panel (Page 4-1) to inspect the Make sure to install it before installing the pulley.
drive and bearings:
Tensioner Pulley Assembly
1. Pivot the belt tensioner away from the belt with
a 3/8 inch drive and remove the belt. Examine Spin the idler pulley. Replace the bearing if it does
the belt for cracks, worn spots and other signs not spin smoothly or is noisy. Replace the idler as-
of deterioration. Replace the belt if necessary sembly if it does not pivot smoothly from one end of
or if it has been in service 5 years or 2000 its travel to the other. Torque the center pivot bolt
hours. 45 lb-ft (60 N-m).
2. Remove the drive pulley and coupling as an as-
sembly from the flywheel and then the pulley Drive Pulley and Coupling
from the coupling. Examine the coupling for
wear and deterioration and replace it if neces- Remove the drive pulley and coupling as an assem-
sary. Examine the two split-sleeve bearings in bly from the flywheel. Then, if necessary, remove
the pulley hub for wear and scoring and replace the 4 coupling nuts on each end to disassemble the
them if necessary. coupling from the hub and the pulley. Examine the
coupling for wear and deterioration and replace it if
When reassembling, torque the coupling nuts necessary. Examine the two split-sleeve bearings in
to 8 lb-ft (12 N-m) and the 4 hub-to-flywheel the pulley hub for wear and scoring and replace
bolts to 21 lb-ft (29 N-m). them if necessary.
3. Spin the idler pulley. Replace the bearing if it
does not spin smoothly or is noisy. Replace the Torque the coupling nuts to 8 lb-ft (12 N-m) and the
idler assembly if it does not pivot smoothly from 4 hub-to-flywheel bolts to 21 lb-ft (29 N-m).
one end of its travel to the other.
Flywheel
4. Spin the generator pulley by hand to determine
if there is any noise, looseness or grinding. Remove the drive pulley and coupling as an assem-
Check for side-to-side and up-and-down loose- bly for access to the flywheel mounting bolts. Scribe
ness of the bearing. If necessary, disassemble a line across crankshaft and flywheel to make re-
the generator (Page 6-2) to determine the alignment easier when reassembling. The flywheel
cause of the looseness or noise. Replace the will only go on one way because the bolts are
rotor assembly if it is evident that either bearing not quite evenly spaced. Proper alignment is
has spun on the shaft. Replace the end bell or necessary to preserve engine balance and tim-
adapter if it is evident that the bearing has spun ing mark.
in the bore. Replace the bearings if they have
been in service 5 years or 2000 hours. Torque the 5 mounting bolts to 42 lb-ft (56 N-m)
when remounting the flywheel.
SERVICE
Engine-Generator Adapter
Generator Pulley
To remove the adapter, first remove the engine-gen-
Remove the belt and pulley center bolt and use a erator assembly from its mounting (Page 4-2), the
claw-type wheel puller to break the pulley free of the generator (Page 6-2) from the adapter and the fly-
generator shaft taper. (To keep the rotor from turn- wheel from the engine. Torque the 6 mounting bolts
ing while loosening the pulley bolt, hold the fan bolt to 21 lb-ft (29 N-m) when reassembling.
7-2
8. Engine
MAJOR ENGINE SERVICE

LINE UP THESE MARKS
WHEN SETTING FUEL
WARNING Accidental or remote starting can INJECTION TIMING
Refer to engine Workshop Manual 981-0533 for

major engine service and for adjusting valve clear-
ance (lash), setting fuel injection timing, replacing
glow plugs, cleaning the crankcase breather as-
sembly and replacing the coolant pump.
Note: To preserve the existing high-idle speed ad-

justment, do not disturb the lock wires on the adjust-
ing screws on the governor actuator base
(Page 8-8) when removing it from the engine for en-
gine service.
Cooling System: Refer to ENGINE COOLING

SYSTEM (Page 3-7) for replacing thermostat, raw
water impeller, heat exchanger and V-belt.
FIGURE 8-1. FUEL INJECTION TIMING MARKS
Fuel Injection Timing Marks: Note the fuel injec-
tion timing marks (Figure 8-1), which line up at
19° BTDC. They are visible when the back or side
panel is removed (Page 4-1).
Adjusting Valve Lash: Do not use the fuel injection

timing marks (Figure 8-1) when adjusting valve
lash. Using them could lead to misadjustments.
Valve lash should be adjusted when both valves are

closed at TDC for the cylinder power stroke (every
other revolution). To locate this position for either
cylinder, rotate the engine clockwise (looking from
the front) until the intake valve push rod (Figure 8-2)
just stops moving down (valve closed). Then turn
the engine one half turn more and adjust lash for
both valves (intake and exhaust). Repeat this pro-
cedure for the other cylinder. Adjust valve lash to
0.0059−0.0073 inch (0.145−0.185 mm).
PUSH ROD, PUSH ROD,
CYL #1 CYL #2
The rocker arm cover is accessible through the top INTAKE VALVE INTAKE VALVE
access opening (Page 4-1). To get the rocker arm
cover off, remove the screw that secures the intake
resonator (Page 8-2) to the cover and tilt the reso-
nator out of the way. Also remove the glow plugs. FIGURE 8-2. ROCKER ARMS AND PUSH RODS
8-1
INTAKE RESONATOR ASSEMBLY clamps will not touch the insulation on the access
door.
WARNING Accidental or remote starting can Before installing the second resonator cham-
cause severe personal injury or death. Before ber, make sure that:
removing a panel or access door, disconnect • The brush block leads are connected
the negative (−) cable at the battery to prevent (Page 6-3).
• The fuel lines are connected at the fuel injector
(Page 8-5).
Figure 8-3 illustrates how the intake resonator sys-
• The oil fill hose is connected at the engine fill
tem is assembled. The arrows indicate the air flow.
tube (Page 8-5).
Remove the top access door and the control access
panel on the left side for access (Page 4-1). When • All adjustments to the governor (Pages 8-7
reassembling, make sure the tails on the hose and 8-8) have been completed.
BREATHER HOSE RUBBER SLEEVE FOR ENGINE INTAKE COLLAR

MUST EXTEND 1/2 INCH APPLY SOAP SOLUTION TO OUTSIDE SO THAT
(10−15 MM) INTO RESONATOR RESONATOR WILL SLIDE ON EASILY
(USE SOAP SOLUTION)
FIRST
INTAKE RESONATOR
CHAMBER
SECOND
INTAKE RESONATOR
CHAMBER
DRAIN HOSE
TIE TO EXHAUST HOSE TO PREVENT
CONTACT WITH RING GEAR AND EXTEND GENERATOR END
1/2 INCH (10−15 MM) INTO RESONATOR AIR INLET BELL THIS SIDE
(USE SOAP SOLUTION)
FIGURE 8-3. INTAKE RESONATOR ASSEMBLY
8-2
EXHAUST MANIFOLD Figure 8-4 illustrates how the exhaust system is as-
sembled. Remove the front and top access doors
WARNING Accidental or remote starting can and the right side panel for access (Page 4-1).
removing a panel or access door, disconnect Use new manifold and mixer gaskets when re-
the negative (−) cable at the battery to prevent assembling. Torque the 4 manifold nuts and the 3
the engine from starting. mixer bolts to 8 lb-ft (11 N-m).
MANIFOLD COOLANT SYSTEM FILL

GASKET AND PRESSURE CAP
EXHAUST MANIFOLD /
COOLANT RESERVOIR
MANIFOLD
STUD, FLAT
SEE ENGINE COOLING GASKET WASHER AND
SYSTEM (PAGE 3-7) NUT(4)
REGARDING HEAT
EXCHANGER AND HOSE
CONNECTIONS
HIGH EXHAUST
WATER−EXHAUST TEMPERATURE
MIXER SWITCH
FIGURE 8-4. EXHAUST MANIFOLD
8-3
FUEL SYSTEM than 1-1/2 minutes to fill a 1 liter container
(2/3 liter per minute).
WARNING Diesel fuel is combustible and can 3. If flow is less than specified, service all of the
cause severe personal injury or death. Do not fuel filters in the system and repair any restric-
smoke near fuel tanks or fuel-burning equip- tions to fuel flow. If fuel delivery is still weak, re-
ment or in areas sharing ventilation with such place the fuel lift pump.
electrical arcs and switches and all other Fuel Pump Removal and Installation: Remove
sources of ignition well away. Keep a multi- the right side panel for access (Page 4-1). Alterna-
class ABC fire extinguisher handy. tively, if the starter has been removed from the front,
the fuel pump can also be removed from the front.
Figure 8-5 illustrates how the fuel system is as-
sembled for delivering fuel to and from the fuel injec- Fuel Fittings: The connections for fuel supply and
tion system. return that extend through the side of the drip pan
are pipe thread fittings. For these fittings use liquid-
type pipe thread sealant Listed as suitable for diesel
fuel. Apply the sealant sparingly to the male threads
only.
the negative (−) cable at the battery to prevent CAUTION Excess liquid-type pipe thread seal-
the engine from starting. ant or pieces of Teflon-type pipe thread sealant
can plug the engine fuel system. Apply liquid-
Fuel Filter: See the engine Workshop Manual type pipe thread sealant sparingly to the male
(981-0533) for fuel injection system service. See threads only. Do not use Teflon tape.
DRAINING / CHANGING FUEL FILTER (Page 3-5)
regarding fuel filter maintenance. Fuel Hose: Replace worn or damaged fuel hose
with with USCG TYPE A1 or ISO 7840-A1 fuel hose.
Fuel Pump Tests: A quick test to determine if the The hoses must be long enough to be clamped and
fuel pump is weak is to pinch the fuel bypass hose to be routed underneath the engine oil pan without
(Figure 8-5) with rubber tipped visegrips. If an en- rubbing on the oil pan.
gine that fails to start starts and runs with bypass
flow cut off, fuel delivery to the engine is weak. Ser- Note: The second intake resonator chamber
vice all of the fuel filters in the system and repair any (Page 8-2) must be removed to connect and discon-
restrictions to fuel flow. If fuel delivery is still weak, nect the supply hose at the fuel injector.
replace the fuel lift pump.
GLOW PLUGS
To test fuel lift pump delivery: Refer to engine Workshop Manual 981-0533 when
1. Disconnect the fuel return hose from the line to replacing the glow plugs (Figure 8-5).
the supply tank and point the end into a contain-
er of known volume, such as a 1 or 2 liter (quart) Note: If a glow plug does not come out after un-
bottle. screwing it, or the end has broken off, it will be
necessary to remove the engine head. Glow
2. Prime the genset by pushing the Start/Stop plugs can swell if preheat voltage is greater than
switch to STOP(Prime) and holding it there for 14 volts, such as when a battery booster is used
the duration of the test. It should not take longer for starting.
8-4
GLOW PLUGS
(2)
CLAMP
WIRE
TIE HOSE FROM PUMP
MUST CROSS OVER
HOSE TO ENGINE
FOR THE QUICK

PUMP TEST,
PINCH HERE TO
CUT OFF BYPASS
FUEL FLOW NOISE
SEAL
OIL FILL
ASSEMBLY
SUPPLY
FUEL LIFT
PUMP
FUEL
FILTER RETURN
FIGURE 8-5. FUEL SYSTEM AND GLOW PLUGS
8-5
GOVERNOR ACTUATOR Stator: Remove the front and top access doors for
access (Page 4-1). To remove the stator, discon-
The position of the rotor in governor actuator A12 nect the 2 actuator leads and remove the cover and
(Figure 8-6) is determined by the modulated pulse 4 stator screws. Pry out the leg of the return spring
width of the current supplied by controller A1. with a screwdriver. (Be prepared to catch the spring
if it flies off.) Lift off the bearing carrier and stator.
Assembly / Disassembly
WARNING The spring can fly off and cause se-
WARNING Accidental or remote starting can vere eye injury. Wear safety glasses.
removing a panel or access door, disconnect Stator reassembly is the reverse of disassembly.
the negative (−) cable at the battery to prevent The bearing carrier must seat squarely in the stator.
the engine from starting. Torque the stator screws to 24 lb-in (2.7 N-m).
SPRING, SHAFT, BEARING ASSEMBLY SNAP-ON COVER
SPRING LEG
MUST CATCH
UNDERNEATH
FUEL RACK
RETURN SPRING
ROTOR
RETAINER
RING
ROTOR
BEARING
SHAFT CARRIER
TERMINALS
BASE STATOR
FIGURE 8-6. GOVERNOR ACTUATOR
8-6
Replace the return spring if it is worn. This spring re-
turns the fuel rack to the no-fuel position. Push the
spring on over the flat on the shaft and pry the leg
into its slot (Figure 8-6). The leg below the knee
must catch underneath and the spring must be
pushed down as far as it will go.
CAUTION The genset may not stop reliably if
the fuel rack return spring is not assembled
properly.
Use wire ties to secure the cover.
Rotor: The rotor can be pried off the shaft after the
bearing carrier has been removed.
Use a new retainer ring when reassembling. Note
that the ring is concave (dished). Push the dished
side up against the rotor to keep it in place on the ACTUATOR SPEED
CONTROL LEVER
shaft. STOP SCREW
Base: See engine Workshop Manual 981-0533 if it
FIGURE 8-7. SPEED CONTROL LEVER STOP
is necessary to remove the actuator base or replace
internal engine governor parts. The stator must be
removed for access to the screws that secure the
base to the engine.
Note: To preserve the existing high-idle speed ad-
justment, do not disturb the lock wires on the adjust-
ing screws on the governor actuator base
(Page 8-8) when removing it from the engine for en-
gine service.
Adjusting Speed Control Lever Stop
The actuator speed control lever stop (Figure 8-7)
must be adjusted whenever a different actuator
base assembly is installed. The stop screw, rather
than the fuel rack control lever, must stop the speed
control linkage when the fuel rack is driven to the no-
fuel position.
Note: To adjust the stop, the rotor need not be on the
shaft, but the end of the shaft must be supported by
the bearing carrier.
1. Remove the front and top access doors
(Page 4-1) and loosen the front / left side panel
assembly so that it can be swung to the left for
access to the adjusting screw.
2. Loosen the stop screw locknut and back the
screw out a few turns. (Top one in the group of
three.)
3. Turn the stop screw in until it just makes contact
and set the locknut.
8-7
Adjusting High-Idle Speed
WARNING This adjustment involves operating
the genset with enclosure panels removed that
guard against moving parts that can cause se-
vere personal injury or death. Keep your hands
away from the engine belt and pulleys.
High-idle speed (Figure 8-8) must be checked each
time an actuator base is reinstalled or replaced.
For an initial adjustment when installing a new base,
(to make sure the engine stops when the actuator is
deenergized), turn the high-idle speed adjusting
screw in until the head of the screw is 3/4 inch
(19 mm) from the base (Figure 8-8).
Note: Be prepared, if necessary, to clamp off the sup- CLAMPING
SCREW
ply and the return fuel lines to stop the engine.
1. Adjust the speed control lever stop (Page 8-7).
SPEED
2. For this test, measure engine speed with a ADJUSTING
strobe or injector clamp-on type tachometer. SCREW
3. Remove the front and top access doors
(Page 4-1) and loosen the front / left side panel
assembly so that it can be swung to the left for
access to the speed adjusting screw.
4. Disconnect the actuator leads and connect a
12 volt battery to the actuator terminals using a
battery switch. (The battery will hold the gover-
nor mechanism against the high speed stop
and allow the engine to run after shutdown—
probably Code No. 15.)
CAUTION The actuator could overheat if
the battery is left on more than 10 minutes.
3/4 inch
5. When ready, switch the battery on, start the 19 mm
genset, measure engine speed (rpm) and stop
the engine by switching off the battery.
6. Readjust high-idle speed, as follows, if not be- FIGURE 8-8. HIGH-IDLE SPEED SCREW
tween 3300 and 3400 rpm:
A. Loosen the lock nuts on the two bottom
screws and back out the clamping screw.
B. To increase speed, turn the speed adjust-
ing screw in 1 turn (clockwise). To de-
crease speed, turn it out 1 turn (counter-
clockwise).
7. Repeat Steps 5 and 6 until high-idle speed is
between 3300 and 3400 rpm. Set the lock nut.
8. Run the clamping screw in by hand until snug,
back it out 1-1/2 turns and set the lock nut.
8-8
STARTER able for rebuilding the starter. Torque the mounting
bolts to 29 lb-ft (39 N-m). Make sure starter B+ is
WARNING Accidental or remote starting can connected to genset B+.
removing a panel or access door, disconnect Negative (Ground) Connection: Before installing
the negative (−) cable at the battery to prevent the starter motor, make sure that the engine block is
the engine from starting. grounded properly, depending on whether standard
or isolated ground connections are required (Fig-
Starter Removal and Replacement: The starter ure 8-9). The star washer must be installed between
motor (Figure 8-9) is accessible for removal and the engine block and cables. Torque the bolt to
installation by removing the right side enclosure 41 lb-ft (55 N-m).
panel (Page 4-1). Alternatively, it can be removed
and installed through the front access opening if the Ground Isolation Relay K9: The relay is accessi-
raw water pump is removed (Page 3-10) and the ble after the starter or side panel has been removed.
fuel filter bracket is unbolted from the drip pan and Replace the relay if its contacts do not close when
moved out of the way (Page 8-5). Parts are avail- 12 VDC is applied to the coil terminals.
STANDARD GROUND CONNECTIONS ISOLATED GROUND CONNECTIONS
OIL PRESSURE
SENDER E1
+ _
STARTER B+
ENGINE
BLOCK
ENGINE
BLOCK
ISOLATION
RELAY K9
STARTER B+ _ +
FIGURE 8-9. STARTER MOTOR MOUNTING AND CONNECTIONS
8-9
9. Troubleshooting
TABLE 9-1 lists the shutdown codes in numerical or- repeat the blinking. The number of blinks is the
der along with step-by-step corrective actions. First shutdown code. Blinking continues for five min-
note the following: utes and stops. Pressing STOP three times restores
blinking. (If you press STOP again, blinking stops
• Maintaining engine oil and coolant levels,
entirely and you have to start over by pressing
cleaning the sea water strainer, keeping battery
STOP three times.)
connections clean and tight, watching the fuel
gauge and not overloading the genset will pre- • One blink indicates shutdown due to high en-
vent most shutdowns. gine temperature.
• When the genset and propulsion engines share • Two blinks indicate shutdown due to low oil
a common fuel tank, the fuel dip tubes are usu- pressure.
ally arranged so that the genset will run out of • Three blinks indicate shutdown due to a condi-
fuel first. Marking the genset empty point on the tion normally requiring service by a trained and
fuel gauge will make it easier to tell when to stop experienced person. To access the second-
the genset before running it out of fuel. level, two-digit shutdown code, press STOP
Break-Out Tool 420−0624 once. The two-digit code consists of 1 to 6
blinks, a brief pause, and then 1 to 9 blinks. The
Break-out tool 420−0624 for use in conjunction with first set of blinks represents the tens digit and
an accurate digital multi-meter is available for pre- the second set of blinks the units digit of the
forming stator winding output tests while running the shutdown code number. For example, Shut-
generator set. The tool is plugged into the generator down Code No. 23 blinks as follows:
set wiring harness in place of the generator set con- blink-blink—pause—blink-blink-blink—long pause—repeat
trol. Follow the tool instructions.
• Four blinks indicate shutdown due to a failure
to start within the time allowed for cranking.
• Seven blinks indicate shutdown due to a loss
SHUTDOWN CODES of raw water flow for engine and exhaust cool-
ing.
The genset controller provides extensive diagnos-
tics by causing the amber status lamp on the control Note: The last shutdown logged will blink, even
switch to blink. Following a shutdown, the indicator though the condition that caused shutdown has
lamp will blink 1, 2, 3, 4 or 7 times, pause, and then been serviced.
9-1
TABLE 9-1 . TROUBLESHOOTING
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, electric-
ity, 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 start-
ing.
NO POWER—GENSET RUNNING, RUN LAMP ON

(Line circuit breaker OFF or tripped)
Corrective Action:
1. Turn on, reset or repair line circuit breaker CB3 on the genset (Page 5-5).
2. Turn on, reset or repair the line circuit breakers on the main distribution panel in the boat.
STARTER ENGAGES-DISENGAGES
(Cranking voltage dips below 6 volts—low battery charge, poor connections, long cables)
Corrective Action:
1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery and gen-
set (Page 3-6).
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Increase battery cable size or run parallel cables.
RUN-DOWN STARTING BATTERY

(Marginal battery, connections or charging system, or parasitic loads)
Corrective Action:
1. Clean and tighten the positive (+) and negative (−) battery cable connections at the battery and gen-
set (Page 3-6).
3. Service the boat battery charging system or the genset battery charger (Page 5-6), if used.
ENGINE CRANKS, STARTS, ACCELERATES, BUT STOPS WHEN SWITCH LET GO

(Open field or open or grounded quadrature circuit)
Corrective Action: Check for an open field or open or grounded quadrature circuit (Page 6-4) and ser-
vice as necessary.
9-2
TABLE 9-1 . TROUBLESHOOTING (CONT.)
ing.
NO LIGHTS, NO RESPONSE
(Poor connections, faulty wiring or dead battery)
Corrective Action: (Refer to Pages A-1 and A-2 when tracing wiring and connectors below.)
1. Try the local genset control switch (S4) if the remote control switch (S11) does not work, and vice
versa. If neither works, go to Step 2. If only local switch S4 works, go to Step 10. If only remote switch
S11 works, go to Step 11.
2. At the genset control panel, push emergency stop switch CB1 to ON.
3. Clean and tighten the positive (+) and negative (−) battery cable terminals at the battery and genset
(Page 3-6).
5. Disconnect both leads from emergency stop switch CB1 (Page 5-1). Check for B+ at lead CB1-1.
If there is no B+, clean and tighten connections and replace wiring as necessary. If there is B+, recon-
nect the lead and check for B+ at switch terminal 2, with the switch ON and then OFF. Replace switch
CB1 if B+ does not turn on and off.
6. Disconnect connector P1 (black) from controller A1 (Page 5-1) and check for B+ at Pin 6. If there
is no B+, check for a missing, bent or corroded pin and faulty wiring and repair as necessary.
7. Disconnect connector P2 (grey) from controller A1 (Page 5-1) and check for continuity between
Pin 1 and B− (ground). If open, check for a missing, bent or corroded pin and faulty wiring and repair
as necessary.
8. While P1 and P2 are disconnected, disconnect the connector on control switch S4. Check continuity
between between the following points: P1-7 and S4-2, P2-3 and S4-1, P2-2 and S4-3, P2-4 and
S4-6, and P2-5 and S4-8. If open, check for missing, bent or corroded pins and faulty wiring and re-
pair as necessary.
9. Replace controller A1 (Page 5-4).
10. Disconnect remote connector P4 and check for continuity in the remote wiring by checking continuity
between pins 4 and 3 when the remote switch is held at START and between Pins 4 and 2 when the
remote switch is held at STOP. Repair or reconnect the remote wiring as necessary.
11. Disconnect the connector on control switch S4 and check that the lamps light when B+ is applied
and that there is continuity across the switch terminals in both positions (Page 5-4). Replace switch
S4 if faulty.
HIGH ENGINE TEMPERATURE—CODE NO. 1

(First-level shutdown—Engine coolant temperature exceed design limit)
Corrective Action:
1. Add coolant as necessary and repair leaks (Page 3-7).
2. Replace the engine thermostat, which might not be opening fully (Page 3-9).
3. Clean the raw water tubes in the heat exchanger, which might be clogged with scale (Page 3-12).
4. Flush the coolant system to remove coolant passage fouling (Page 3-8).
5. Test coolant sender E2 (Page 5-5) and replace if necessary.
9-3
ing.
LOW OIL PRESSURE—CODE NO. 2

(First-level shutdown—Low oil pressure)
1. Add engine oil as necessary (Page 3-3).
2. Drain excess oil (above top bead on dipstick).
3. Disconnect connector P1 (black) from controller A1 (Page 5-1) and measure resistance between
Pin 10 and B− (ground). If resistance is greater than 257 Ohms, check for a missing, bent or corroded
pin or faulty wiring or loose ring terminal on sender E1 (Page 5-5). Repair as necessary.
4. Replace the sender with a gauge, ground the sender wire (to keep engine running) and start the en-
gine. Shut down the engine immediately if there is no oil pressure.
A. If engine oil pressure is less than 14 psi (98 kPa), service the oil lubricating system (Page 8-1).
B. If engine oil pressure is at least 14 psi (98 kPa), test oil pressure sender E1 (Page 5-5) and re-
place if necessary. Replace controller A1 (Page 5-1) if sender E1 is in working order.
SERVICE CHECK—CODE NO. 3

(First-level shutdown—Indicates presence of second-level shutdown)
Corrective Action: Check the second-level shutdown code by pressing STOP once. The second-level
shutdown code will have two-digits. The shutdowns are listed below in numerical order.
9-4
ing.
OVERCRANK—CODE NO. 4
(First-level shutdown—Cranking exceeded 20 to 60 seconds [temperature dependent] without start)
1. 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.)
2. Open any closed fuel valves.
3. Remove any blockage in the combustion air inlet (lower rear of left side) or exhaust system.
4. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction.
5. Drain the fuel filter of water and sediment (Page 3-5) and prime the fuel system (Page 2-2).
6. Replace the fuel filter (Page 3-5) and prime the fuel system (Page 2-2).
7. Drain and/or replace fuel supply system filters and prime the fuel system (Page 2-2).
8. Conduct a fuel pump flow test and service as necessary (Page 8-4).
9. Inspect and service the glow plugs (Page 8-4) as follows:
A. If loose, tighten the glow plug terminals.
B. Check for B+ at the glow plug terminals during cranking. If there is no B+, remove glow plug
relay K3 from its socket and test for proper operation (Page 5-6). Replace if necessary. Also
check for B+ at relay socket terminal 30, for continuity between terminal 87 and the glow plugs
and for continuity between terminal 86 and B− (ground). Clean and tighten connections and re-
place wiring as necessary.
C. Check for B+ at relay socket terminal 85 while cranking. If there is no B+, disconnect connector
P3 (green) from controller A1 (Page 5-1) and check for a missing, bent or corroded pin and faulty
wire and repair as necessary. If the wire and connections are good, replace controller A1.
D. Remove the glow plug bus bar and check for electrical continuity between each glow plug termi-
nal and B− (ground). Replace any open glow plug (Page 8-4).
10. Remove the front and top access doors and door lintel (Page 4-1) and the cover on the governor
actuator (Page 8-6). Reattach the governor leads and observe the actuator rotor while cranking. The
rotor should rotate smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the ac-
tuator terminals and observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does,
go to Step C.
A. Check resistance across the actuator terminals with an accurate digital ohmmeter. If resistance
is not between 1.7 and 2.8 ohms, replace the actuator stator.
B. Push the actuator rotor by hand (clockwise) to check for binding in the governor mechanism.
It should rotate smoothly and return smoothly. If it binds or catches, remove the bearing carrier
and stator and look for signs of physical contact between rotor and stator and service as neces-
sary. If there are no signs of contact, remove the governor base. Replace the base or service
the internal engine governor mechanism, as necessary (Page 8-1).
C. Disconnect connector P1 (black) from controller A1 (Page 5-1) and measure resistance be-
tween Pin 5 and A12+ and between Pin 12 and A12−. If either lead is open, check for a missing,
bent or corroded pin or faulty wiring and repair as necessary.
D. Replace controller A1 (Page 5-1).
11. Service the engine (Page 8-1).
9-5
ing.
LOSS OF RAW WATER FLOW—CODE NO. 7

(First-level shutdown—Low raw water pressure in heat exchanger)
1. Open the sea cock all the way.
2. Close the sea cock and clean the sea water strainer. If the strainer is above the water line, fill it with
water to assist priming. Secure the strainer cover and reopen the sea cock.
3. Reconnect or replace any disconnected or leaking raw water hoses (Page 3-7).
4. Remove any blockage from the strainer on the through-hull fitting on the bottom side of the hull.
5. Replace the raw water impeller (Page 3-10).
6. Remove the top access door and check the two leads to flow switch S6 (Page 5-6). Reconnect and
clean if loose or corroded.
7. Check for continuity between S6-2 and B− (ground). If open, clean and tighten connections and re-
place wiring as necessary.
8. Disconnect connector P1 (black) from controller A1 (Page 5-1) and check for continuity between
Pin 4 and S6-1. If open, check for a missing, bent or corroded pin and faulty wiring and repair as nec-
essary.
9. Test flow switch S6 (Page 5-6) and replace if necessary.
OVERVOLTAGE—CODE NO. 12
(Controller unable to maintain rated voltage)
Corrective Action:
1. Push line circuit breaker CB3 (Page 2-1) to OFF, start the genset and measure output voltage. If out-
put voltage is normal, the problem is in the circuits external to the genset. If there is no voltage, test
for grounded field, stator or quadrature windings (Page 6-4). Replace a stator or rotor with faulty
windings.
2. Check for proper connections of the field sense leads (T1, T2) and reconnect as necessary
(Page 6-6).
9-6
ing.
UNDERVOLTAGE—CODE NO. 13
(Controller unable to maintain rated voltage)
Corrective Action:
1. Push line circuit breaker CB3 (Page 2-1) to OFF, start the genset and measure output voltage. If out-
put voltage is normal, go to Step 2. If output voltage is low, go to Step 3.
2. Reduce the number of connected appliances, especially when air conditioners and battery chargers
are running.
3. Service the brushes and slip rings as necessary (Page 6-3) and test the generator field, stator and
quadrature windings for opens and shorts (Page 6-4). Replace a stator or rotor with faulty windings.
OVERFREQUENCY—CODE NO. 14
(Engine governor unable to maintain rated frequency)
Corrective Action:
1. If line circuit breaker CB3 or any other circuit breaker has tripped, start the genset before resetting
the breaker. (Frequency can overshoot when a circuit breaker trips under load.) If the genset contin-
ues to run, turn off or disconnect all loads, reset the breaker and bring the loads on one at a time
without overloading the genset. If the genset shuts down again, go to Step 2.
3. Prime the fuel system to remove air in the fuel lines (Page 2-2).
4. Remove the front and top access doors and door lintel (Page 4-1) and the cover on the governor
actuator (Page 8-6). Reattach the governor leads and observe the actuator rotor while cranking. The
rotor should rotate smoothly through about 1/2 inch (12 mm). If it does not, apply 12 VDC to the ac-
tuator terminals and observe whether the rotor rotates smoothly. If it does not, go to Step A. If it does,
go to Step C.
9-7
ing.
UNDERFREQUENCY—CODE NO. 15
(Engine governor unable to maintain rated frequency)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
6. Replace the fuel filter (Page 3-5) and prime the fuel system (Page 2-2).
9. Remove the front and top access doors and lintel (Page 4-1) and the governor actuator cover
(Page 8-6) and observe the actuator rotor while cranking. (Remember to reattach the leads after re-
moving the cover.) The rotor should rotate smoothly through about 1/2 inch (12 mm). If it does not,
check for binding in the governor mechanism by pushing the actuator rotor clockwise by hand
(against the fuel rack return spring). It should rotate smoothly about 1/2 inch (12 mm) and return
smoothly. If it binds or catches, remove the governor actuator base assembly and replace it, or ser-
vice the internal engine governor mechanism as necessary (Page 8-1).
10. Readjust high idle speed (Page 8-8).
11. Service the fuel injectors and injection pump as necessary (Page 8-1).
12. Check fuel injection timing (Page 8-1).
9-8
ing.
OVER-PRIME—CODE NO. 17
(Prime mode exceed 5 minutes)
Corrective Action:
1. Check for and remove any object that may be holding either control switch (remote or local) in the
prime position.
2. Disconnect remote connector P4 and check for continuity between Pins 4 and 2 when the remote
switch is not held at STOP. If there is continuity, repair or reconnect the remote wiring as necessary.
3. Disconnect the connector on control switch S4 and check for continuity between terminals 1 and 2
when the switch is not held at STOP (Page 5-4). If there is continuity, replace switch S4.
9-9
ing.
GOVERNOR OVERLOAD—CODE NO. 22

(Maximum allowable time at full-duty cycle was exceeded)
Corrective Action:
9. Readjust high idle speed (Page 8-8).
10. Service the fuel injectors and injection pump as necessary (Page 8-1).
11. Check fuel injection timing (Page 8-1).
9-10
ing.
FAULTY OIL PRESSURE SENDER—CODE NO. 23

(Controller sensed grounded sender)
1. Disconnect connector P1 (black) from controller A1 (Page 5-1) and measure resistance between
Pin 10 and B− (ground). If there is a short to ground, repair the wiring or test and replace sender E1
(Page 5-5), as necessary.
FAULTY TEMPERATURE SENDER—CODE NO. 24

(Controller sensed open sender)
1. Remove the top access door and tighten the ring terminal on sender E2 (Page 5-5) if loose. (For iso-
lated-ground applications only, connect flag terminal E2-2 if loose. Also check continuity between
E2-2 and B− [ground] and repair wire as necessary.)
2. Measure resistance across sender E2 (Page 5-5) and replace it if open.
3. Disconnect connector P1 (black) from controller A1 (Page 5-1) and check continuity between Pin 9
and ring terminal E2-1. Repair the wiring as necessary if open.
LOSS OF VOLTAGE SENSE—CODE NO. 27

(Controller unable to sense output voltage)
1. Check for and properly reconnect voltage sense leads T1 and T2 (Page 6-6).
2. Disconnect connector P3 (green) from controller A1 (Page 5-1) and check continuity between Pin 11
and T2 and between Pin 12 and T1. If open, check for missing, bent or corroded pins and faulty wiring
and repair as necessary.
HIGH BATTERY VOLTAGE—CODE NO. 29

(Battery system at more than 19.2 volts)
Corrective Action:
1. Check battery bank connections and reconnect if necessary to supply 12 volts.
2. Select a lower external battery boost charge rate.
9-11
ing.
CONTROL CARD FAILURE—CODE NO. 35

(Microprocessor EEPROM error during self-test)
Corrective Action: Replace controller A1 (Page 5-1).
ENGINE STOPPED—CODE NO. 36

(Engine stopped without command by controller)
Corrective Action:
1. Open any closed fuel supply valves.
3. Check for mechanical damage and service as necessary.
4. Remove any blockage in the combustion air inlet (lower rear of left end of genset).
10. Check for an open field or open or grounded quadrature circuit (Page 6-4) and service as necessary.
11. Service the engine (Page 8-1).
9-12
ing.
INVALID GENSET CONFIGURATION—CODE NO. 37

(Controller cannot determine genset operating parameters)
1. Disconnect connector P2 (grey) from controller A1 (Page 5-1) and check continuity between Pin 9
and B− (ground). Pin 9 should not be grounded. Repair the wiring as necessary.
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 left side and front of genset.
3. Have air conditioners and other appliances checked for proper operation. (A locked compressor ro-
tor can cause very low power factor.)
4. Check for a loose generator fan (Page 6-1) and repair or replace as necessary.
GROUNDED ROTOR—CODE NO. 41

(F+ grounded)
1. Disconnect connector P3 (green) from controller A1 (Page 5-1) and check for continuity between
Pin 7 (F+) and B− (ground). Pin 7 should not be grounded. Repair or replace wiring, brushes and
slip rings (Page 6-3) or rotor (Page 6-4), as necessary.
PROCESSOR FAILURE—CODE NO. 42

(Microprocessor ROM error during self-test)

(Microprocessor RAM error during self-test)
9-13
ing.
SPEED SENSE LOST—CODE NO. 45

(After start disconnect the generator set Controller lost speed sense [quadrature zero crossings] for 0.25
seconds).
Corrective Action: Refer to Pages A-1 through A-3 as appropriate.
1. Disconnect connector P3 (green) from the generator set controller and check for open or shorted
field (P3−6—P3−7) or quadrature (P3−4—P3−5) windings (p. 6-4 )Service or replace brush block,
slip rings, rotor, or stator, as necessary.
2. Replace the generator set controller (p. 5-4).

(Controller unable to sense field voltage)
HIGH EXHAUST TEMPERATURE—CODE NO. 58

(Exhaust temperature exceeded design limits)
Corrective Action:
1. Open the sea cock all the way.
2. Close the sea cock and clean the sea water strainer. If the strainer is above the water line, fill it with
water to assist priming. Secure the strainer cover and reopen the sea cock.
3. Reconnect or replace any disconnected or leaking raw water hoses (Page 3-7).
4. Remove any blockage from the strainer on the through-hull fitting on the bottom side of the hull.
5. Replace the raw water impeller (Page 3-10).
6. Disconnect connector P1 (black) from controller A1 (Page 5-1) and check continuity between Pin 11
and B− (ground). If open, check for a missing, bent or corroded pin, faulty wiring or open exhaust
temperature switch S5 (Page 5-6). Repair as necessary.
EMERGENCY SHUTDOWN—CODE NO. 61

(Genset was shut down by a fire suppression system or other external control)
Corrective Action:
1. Make all necessary repairs to the genset and connected equipment and reset the external control
which shut down the genset.
2. Disconnect the external wiring connected at connector J6 and check for B+. If there is B+, find out
why and reconnect or repair the external control circuit.
9-14
612-6752
WIRING DIAGRAM
A-1
GREEN
GREY
BLACK
338-3961
WIRING HARNESS
A-2
0098-8374
GENERATOR CONNECTION DIAGRAM
A-3
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
CumminsR, OnanR, the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
E2009 Cummins Power Generation, Inc. All rights reserved.
A-1

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What are the main components and functions of the generator set?

What are the main components and functions of the generator set?

What are the recommended maintenance procedures for the generator set?

What are the recommended maintenance procedures for the generator set?

Service Manual

Marine Generator Set

MDKAU (Spec A−C)

English − English Original 4−2010 981−0532 (Issue 4)

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE BOAT

WARNING Improper service or replacement of

WARNING Unauthorized modifications or re-

See the Installation Manual for important recom-

See the Parts Manual for part identification numbers

When contacting Onan for parts and product infor-

LINE CIRCUIT BREAKER

CONTROL SWITCH &

HOUR METER OIL FILL NECK

FIGURE 2-1. GENSET CONTROL PANEL

TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE

General Inspection1 x 3-2

WARNING Crankcase pressure can blow hot

2. Add or drain oil as necessary. See ENGINE OIL

CAUTION Too much oil can cause high oil

3. Secure the oil fill plug, which snaps into its

FIGURE 3-3. FUEL FILTER

FIGURE 3-5. ENGINE COOLING SYSTEM

WARNING Hot coolant is under pressure and

See Table 3-1 for scheduled replacement. Refer-

WARNING Accidental or remote starting can

WARNING Accidental or remote starting can

5. Remove the 4 pump cover screws (Fig-

CAUTION Do not lubricate with petroleum

8. Remount the pump, reconnect the hoses, ad-

9. If the sea water strainer is above the water line,

10. Open the sea cock, reconnect the battery IMPELLER

Cleaning and Draining the Heat Exchanger: To

Use thread sealant on the drain plug and a new

Removing/Installing the Heat Exchanger: Re-

To remove the heat exchanger, first disconnect the

To install the heat exchanger, first clean the mating

RIGHT SIDE TOP DOOR FRONT STANDOFF OUTPUT GENSET

FIGURE 4-1. GENSET ENCLOSURE

DRIP RUBBER NOISE

FIGURE 4-2. DRIP PAN AND MOUNTING SYSTEM

OVERVIEW functions required to operate the genset. All con-

GLOW PLUG 2-POLE CIRCUIT CONTROL

FIGURE 5-1. CONTROL SYSTEM COMPONENTS

RAW WATER PRESSURE SWITCH

REMOTE EXHAUST TEMPERATURE SWITCH

FIGURE 5-2. CONTROLLER A1 BLOCK DIAGRAM

ENGINE OIL PRESSURE SENDER E1

Replace the sender if resistance is not between

Replace the sender if resistance is not approximate-

WARNING Accidental or remote starting can

The raw water flow switch is threaded into the heat

HIGH EXHAUST TEMPERATURE SWITCH

The high exhaust temperature switch is bolted to the

GLOW PLUG RELAY K3