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1. FIG 2 3 FAULT No Active Faults HIST FAULT HISTORY Speed Sense Lost Ea udd 45 Hovs 10000 1 16 75 sack M T OR FAULT HISTORY No Stored Faults FIGURE 2 5 FAULT HISTORY v FAULT Eng coolant temp sensor fault Fault No FROM FAULT FIG 2 3 24 PRE ALARM Low Oil Pressure see Status Page 2 for more info OR one eae i No Active Alarms ABACK FIGURE 2 6 ENGINE PRE ALARMS 2 5 Screen Brightness and Contrast FROM SCREEN To adjust the brightness and contrast of the LCD VR y screen and status lamps go to the SCREEN AD SCREEN ADJUST JUST screen by pressing SCREEN on any GEN STATUS screen Press NEXT to select Brightness or Contrast Increase or decrease the selected item Contrast by pressing the increase decrease buttons 4 gt See Figure 2 7 Contrast applies only to the LCD BACK NEXT screen Press 4BACK to save the settings and go back to GEN Si FIGURE 2 7 SCREEN BRIGHTNESS amp CONTRAST Display Setup Go to the SETUP screen by pressing SETUP on any Sass y GEN STATUS screen Press the up down arrows SUP v a to select Display Setup and press ENTER ae See 2 8 wie 4 R DISPLAY SETUP GENSET INFO Units To change the units of measure on the GEN DISPLAY INFO STATUS screens press NEXT to select Units Then press the up down arrows x a to toggle between Metric and
2. tions and safety precautions Keep this manual handy for ready reference Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for op erating the generator set and maintaining it at top performance The owner is responsible for perform ing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE p 4 1 This manual also includes generator set specifications informa tion on how to obtain service and information re garding compliance with emissions regulations This generator set is not a life sup port system It can stop without warning Chil dren persons with physical or mental limita tions and pets could suffer personal injury or death A personal attendant redundant power or alarm system must be used if generator set operation is critical See the Parts Manual for part identification numbers and required quantities Genuine Cummins Onan replacement parts are recommended for best re sults Because this generator set is an Ignition Protected Device no substitutes are permitted for the parts listed in the Critical Parts Index of the generator set Parts Catalog They must be purchased from Onan and be installed in accordance with the generator set Service Manual by those who are trained and experi enced in marine generator set service MODEL IDENTIFICATION Be ready to provide the generator set model and se rial numbers on the nameplate when contacting Onan for parts ser
3. 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 SIZE WEIGHT NOISE Size Lx Wx H Weight dry Noise 60 Hz 50 Hz Trickle 8 amps 26 x 20 1 x 20 6 inch 662 x 511 x 524 mm 365 Ibs 166 kg 71 dB A 68 dB A 7 Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Section 4 HOUR METER MAINTENANCE OR SERVICE PERFORMED m Record the name address and phone number of your authorized Cummins Onan service center Cummins Onan Cummins Power Generation 1400 73rd Ave NE Minneapolis MN 55432 USA Ph
4. SAE units Press 4BACK to save the selection and go back to GEN STATUS DISPLAY SETUP Units AC Voltmeter Calibration To calibrate the Display Voltmeter press NEXT to select AC Voltmeter AC Volt Meter Calibration Then press the up down arrows v 4 Calibration Biv to increase or decrease the voltage displayed to BACK NE a vy correspond to an accurate AC output voltmeter line to line or line to neutral as desired GENSET INFO Press 4BACK to save the selection and go back to GENSET GEN STATUS SW P N 3261234 V12 34 NIM Note This procedure does not change AC output SW P N 3261234 V12 34 voltage Have a trained and experienced person ad just AC output voltage if necessary before calibrat SACK OOOO O ing the Display Voltmeter Generator Set and Display Information DISPLAY INFO SW P N 3261234 Go to the SETUP screen by pressing SETUP on any SW VERSION 12 34 GEN STATUS screen Press the up down arrows SF P N 3261234 v a to select Genset Info or Display Info and press SF VERSION 10 23 ENTER See Figure 2 8 This information may be requested by the service technician Keep pressing 4BACK to get back to GEN STA TUS FIGURE 2 8 SETUP GENSET amp DISPLAY INFO 2 6 3 Operation FUEL Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning equip ment or in areas sharing ventilation with such equi
5. event of fire 1 DO NOT open the generator set enclosure 2 Shut down engines generators and blowers 3 Break through the circle on the label with the nozzle and discharge the full contents of the fire extinguisher 3 2 WARNING In case of fire do not open soundshield Avoid serious injury or death from fire Shut down engines generator sets and blowers Immediately discharge entire contents of gaseous portable fire extinguisher through this port Extinguisher Port 98 7472 FIGURE 3 2 FIRE EXTINGUISHER PORT EXHAUST GAS IS DEADLY All engine exhaust contains carbon monoxide an odorless colorless poisonous gas that can cause unconsciousness and death Symptoms of carbon monoxide poisoning include Dizziness Headache Nausea Vomiting Weakness Sleepiness Inability to Think Clearly GET EVERYONE OUT INTO FRESH AIR IMMEDI ATELY IF ANYONE EXPERIENCES ANY OF THESE SYMPTOMS Seek medical attention if symptoms persist Never sleep in the boat when the generator set 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 generator set and after every eight hours of operation Shut down the generator set immediately if there is a leak Do not run the generator set until the leak has been repaired The exhaust system must be installed in accordance with the gener ator s
6. for the generator set Corrective Action See an authorized Onan service representative FIELD OVERLOAD CODE NO 38 Control Logic High field voltage induced by high rotor temperature or low power factor loads Corrective Action Remove blockages to generator air flow at the front inlet grill and right side if enclosed Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners Have air conditioners and other appliances checked for proper operation A locked compressor rotor can cause very low power factor GENERATOR ROTOR FAULT CODE NO 41 Control Logic F grounded Corrective Action See an authorized Onan service representative 5 8 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting CONTROL CARD FAILURE RAM CODE NO 43 Control Logic During startup the generator set Controller detected a RAM memory error Corrective Action See an authorized Onan service representa
7. is not marked for use in open air Install the generator set in accordance with the Installation manual Obey local noise restric tions where you operate the generator set ELECTROMAGNETIC COMPATIBILITY Generator sets emit and receive electomagnetic radio frequency energy If the generator set affects operation of nearby devices or nearby devices af fect generator set operation increase the distance between them BUILD STANDARDS Note for use in countries where compliance to the EMC directive is required This generator set has been evaluated for use in residential commerical and light industrial environments The generator set and its control system have been designed constructed and tested generally in accordance with the following Standards where applicable refer to Table 1 1 TABLE 1 1 BUILD STANDARS BS EN 1037 1995 A1 2008 Safety of machinery Prevent of unexpected start up BS EN ISO 14121 1 2007 Safety of machinery Risk assessment Principles BS EN ISO 13857 2008 BS EN 349 1993 a1 2008 BS EN 547 1 1996 A1 2008 BS EN 547 2 1996 A1 2008 BS EN 547 3 1996 A1 2008 BS EN 60204 1 2006 A1 2009 BS EN 614 1 2006 A1 2009 BS EN 953 1997 A1 2009 BS EN ISO 12100 1 2003 A1 2009 BS EN ISO 12100 2 2003 A1 2009 BS EN ISO 13732 1 2008 Safety of machinery Safety distance to prevent haz ard zones being reached by upper and lower limbs Safety of machinery Minimum gaps to avoid crush ing part
8. leaks e To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery e Keep the generator set drip pan and compart ment clean Oily rags can catch fire Gear stowed in the compartment can restrict cool ing e Make sure all fasteners are secure and proper ly torqued e Do not work on the generator set when mental ly or physically fatigued or after having con sumed alcohol or drugs e Let the engine cool down before removing the coolant pressure cap or opening the coolant drain Hot coolant under pressure can spray and cause severe burns e Used engine oil has been identified by some U S state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors e Ethylene glycol used as engine antifreeze is toxic to humans and animals Clean up spills and dispose of used engine coolant in accor dance with local environmental regulations e Keep multi purpose fire extinguishers handy Multi purpose fires extinguishers are used for fires that involve ordinary combustible materi als such as wood and cloth combustible and flammable liquid fuels and gasous fuels live electrical equipment North America ref NFPA No 10 e Generator set installation and operation must comply with all applicable local state and fed eral codes and regulations e Generator sets with a sound shield shall n
9. loads when large motors and air con ditioners are cycling on and off The generator set is rated at standard barometric pressure humidity and temperature ref ISO 3046 Either low barometric pressure high al titude or high ambient temperature will decrease 3 4 engine power It may be necessary to run fewer loads under such conditions TABLE 3 1 TYPICAL APPLIANCE LOADS Electric Water Heater 1000 1500 500 1200 Electric Hair Dryer NO LOAD OPERATION Keep no load operation to a minimum During no load operation cylinder temperatures drop to the point where fuel does not burn completely causing fuel wetting and white smoke It is best to run the generator set at 1 4 to 3 4 load CONNECTING TO SHORE POWER When provisions have been made for connecting shore power the boat must have an approved de vice to keep the generator set and shore power from being interconnected Interconnecting the generator set and shore power can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent in terconnections RESETTING LINE CIRCUIT BREAKERS If the generator set line circuit breaker trips p 2 1 or a circuit breaker in the power distribution panel of the boat either a circuit shorted or too many loads were connected Note that the generator set will continue to run after a line circuit breaker trips If a circuit breaker trips disconnect or turn off as m
10. set Service Manu al by those who are trained and experienced in marine generator set service BATTERY GAS IS EXPLOSIVE e Wear safety glasses e Do not smoke e To reduce arcing when disconnecting or recon necting battery cables always disconnect the negative battery cable first and reconnect it last MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Do not wear loose clothing or jewelry near moving parts such as PTO shafts fans belts and pulleys e Keep hands away from moving parts e Keep guards in place over fans belts pulleys and other moving parts FLAMMABLE VAPOR CAN CAUSE A DIESEL ENGINE TO OVERSPEED Do not operate a diesel powered generator set where a flammable vapor envi ronment can be created by fuel spill leak etc Flammable vapor can cause a diesel engine to overspeed and become difficult to stop resulting in possible fire explosion severe personal injury and death The owners and operators of the generator set are solely responsible for operating the genera tor set safely SUBSTANCE HAZARDS TO HEATLH Generator sets use substance and emit and create wastes that can cause health ricks Generator set operators must use appropriate personal protec tive equipment such as clothing gloves protective glasses goggles and respiration equipment when exposed to fuel oil coolant wet batteries grease cleaning agents or other substances exposed to lungs eyes or skin Use approp
11. set circuit breaker if OFF or tripped 2 Reset or turn ON any other circuit breaker in the AC power supply system if OFF or tripped 5 2 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting HIGH ENGINE TEMPERATURE CODE NO 1 Control Logic Engine coolant temperature exceed design limit Corrective Action 1 Open the sea valve 2 Check for and clean a blocked sea water strainer lf above the water line fill the strainer with water to assist priming Check engine coolant level add coolant as necessary and check for and repair leaks p 4 7 Check for and reconnect or replace any disconnected kinked or leaking raw water hoses Check the bottom of the hull for any blockage at the through hull fitting Drain and clean the cooling system to remove fouling p 4 7 Replace the coolant thermostat which might not be opening fully p 4 10 LOW OIL PRESSURE CODE NO 2 Control Logic Low oil pressure Corrective Action Check engine oil lev
12. than several shorter periods Exercising a generator set drives off moisture re lubricates the engine uses up fuel before it becomes stale and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life STORING THE GENERATOR SET Proper storage is essential for preserving top gener ator set performance and reliability when the gener ator set cannot be exercised regularly and will be idle for more than 120 days Storing the Generator Set 1 Turn off the generator set line circuit breaker p 2 1 2 Change the engine oil and filter and attach a tag indicating oil viscosity See ENGINE OIL REC OMMENDATIONS p 3 1 3 Crank the engine several revolutions but do not let it start This will fill the oil passages with the new oil 4 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufac turer s recommendations See MAINTAINING THE BATTERY AND BATTERY CONNEC TIONS p 4 3 5 Check coolant level and add as necessary p 4 7 Test the coolant mixture if freezing temperatures are possible and change if nec essary 3 6 Hot coolant is under pressure and can cause severe burns when loosen ing the pressure cap Let the engine cool before loosening the pressure cap 6 Drain the heat exchanger and muffler if freezing temperatures are expected 7 Clean and lightly oil par
13. the nearest Cummins Onan distributor in the United States or Canada Press 1 OPTION 1 to be automatically connected If you are unable to contact a distributor using the automated service consult the Yellow Pages Typi cally our distributors are listed under GENERATORS ELECTRIC Outside North America Call Cummins Power Generation at 1 763 574 5000 from 7 30 AM to 4 00 PM Cen tral Standard Time Monday through Friday or fax 1 763 528 7229 Information To Have Available 1 Model Number including Spec Letter and Seri al Number Figure 1 1 2 Date of purchase 3 Nature of problem Section 5 Troubleshoot ing 1 2 EMISSIONS LABEL The label that states compliance with applicable en gine emissions regulations is located as shown on the engine Figure 1 2 Refer also to the FEDERAL EMISSION DESIGN AND DEFECT LIMITED WAR RANTY FOR C I ENGINES DIESELS that was shipped in the same package as the Operator Manual ENGINE EMISSIONS FIGURE 1 2 EMISSIONS LABEL NOISE Generator sets emit noise As noise level and time of exposure increase risk of hearing damage in creases The Specifications page in the Operator manual states noise level for this generator set Se lect and use personal hearing protection appropri ate for your exposure to generator set noise Note for use in countries where compliance to the EU Noise directive is required This generator set has not been evaluated and
14. 3 For longer engine life let the engine warm up for two minutes before connecting air condi tioners and other large electrical loads Monitor generator set status using the e Series Digital Display p 2 3 if so equipped Perform maintenance or service as necessary if the Dis play indicates a Pre Alarm condition p 2 2 If the generator set fails to start cranking will discontinue in 20 to 60 seconds depending on engine temperature The e Series Digital Dis play and or control switch status lamp will indi cate Fault Code No 4 See Troubleshooting Section 5 if the generator set does not start af ter several tries Do not continue cranking and risk burning out the starter or flooding the engine exhaust flow during cranking is too low to expel water from a wet exhaust sys tem Find out why the generator set does not start and make necessary repairs If the generator set shuts down the e Series Digital Display and or control switch status lamp will indicate the numeric fault code See Troubleshooting Section 5 STOPPING THE GENERATOR SET Disconnect all electrical loads to let the generator set run without load and cool down After 2 minutes Push and Release STOP on the e Series Digital Display or control switch The generator set status lamps will go out After Boil can force large amounts of coolant through the pressure cap and coolant recovery tank Always let the engine cool down before stop
15. 7 32 38 43 48 FIGURE 3 1 OIL VISCOSITY GRADE VS AMBIENT TEMPERATURE ENGINE COOLANT Ethylene Glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances Use the best quality ethylene glycol antifreeze solu tion available It should be fully formulated with rust inhibitors and coolant stabilizers A 50 50 mixture of water and ethylene glycol is recommended to pro vide protection from freezing down to 34 F 37 C Use fresh water that is low in minerals and corrosive chemicals for the coolant mixture Distilled water is best See Specifications Section 6 regarding coolant capacity BATTERIES Reliable generator set starting and starter service life depend upon adequate battery system capacity and maintenance See MAINTAINING THE BAT TERY AND BATTERY CONNECTIONS p 4 3 and Specifications Section 6 FIRE EXTINGUISHER PORT The boat must have a fire extinguisher readily avail able for putting out a fire in the genset It must be ap proved for both liquid fuel and electrical equipment A generator set with an enclosure has a fire extin guisher port accessible by breaking through the circle on the warning label located as shown in Fig ure 3 2 Make sure that the nozzle of the fire extinguisher that will be used in the event of fire is smaller than the circle so that it will fit through the port The fire extinguisher must be of the gaseous type In the
16. Belt Tensioner amp Drive Coupling Every 5 Years 2000 Hrs Every 800 Hrs Every 2 Years x8 mie Includes inspection of Oil Level Coolant Level Fuel System Exhaust System Batteries and Sea Water Strainer See battery manufacturer s recommendations Check for slippage cracking and wear pump drive belt only There is no zinc anode to replace Must be performed by a trained and experienced mechanic Onan Distributor Dealer in accordance with the engine and gener ator set Service Manuals 4 1 GENERAL INSPECTION Inspect the generator set before the first start of the day and after every eight hours of operation Oil Level Check engine oil level p 4 4 Exhaust System EXHAUST GAS IS DEADLY Do not operate the generator set until all exhaust leaks have been repaired Inspect the exhaust system for leaks and loose hose clamps at the exhaust manifold exhaust el bow muffler water separator and hull fittings Re place damaged sections of exhaust hose Check that all CO monitors are working properly Fuel System Fuel leaks can lead to fire Repair leaks immediately Do not run the generator set if it causes fuel to leak Check for leaks at hose tube and pipe fittings in the fuel supply and return systems while the generator set is running and while it is stopped Check flexible fuel hose for cuts cracks abrasions and loose hose clamps Make sure fuel lines do not rub against ot
17. ERATOR MANUAL be fore operating the generator set Safe operation and top performance can only be obtained when equipment is operated and maintained properly Only trained and experienced service person nel with knowledge of fuels electricity and ma chinery hazards shall remove dismantle and dispose of the generator set See service manu al Some generator set installation procedures presend hazards that can result in severe per sonal injury or death Only trained and experi enced personnel with knowledge of fuels elec tricity and machinery hazard should perform generator set installation procedures The following symbols in this manual alert you to potential hazards to the operator service person and equipment alerts you to an immediate hazard that will result in severe personal injury or death alerts you to a hazard or unsafe practice that can result in severe personal inju ry or death alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage Electricity fuel exhaust moving parts and batter ies present hazards which can result in severe per sonal injury or death GENERAL PRECAUTIONS e Keep children away from the generator set e Do not use evaporative starting fluids They are highly explosive Do not step on the generator set when entering or leaving the generator room Parts can bend or break leading to electrical shorts or to fuel coolant or exhaust
18. Generic stan BS EN 61000 6 1 2007 dards Immunity standard for residential commercial and light industrial environments Electromagnetic compatibility EMC Generic stan BS EN 61000 6 3 2007 dards Emission standard for residential commercial and light industrial environments Mechanical vibration and shock Vibration isolation BS EN 1299 1997 A1 2008 of machines Information for the application of source isolation Reciprocating internal combustion engines Saftey Part 1 Compression ignition engines Reciprocating internal combustion engine driven BEN 126880 1 generating sets Safety 1 4 2 Operator Control Panels LOCAL CONTROL Refer to Figure 2 1 Control Switch Starting Push and Hold START to preheat crank and start the generator set The green status lamp comes on when the generator set is running Pre heat is the period of time prior to engine cranking when the glow plugs preheat the combustion cham bers The time is automatically varied by the gener ator set controller on the basis of engine tempera ture Stopping Push and Release STOP Prime to stop the generator set Priming Push and Hold STOP Prime to prime the fuel system amber lamp comes on in 2 seconds to indicate priming Status Lamps The control switch has two status lamps The amber status lamp comes on during priming blinks rapidly during cranking and goes out when the engine is up to speed If the generator set sh
19. LESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting FAULTY TEMPERATURE SENDER CODE NO 24 Control Logic Controller sensed open sender Corrective Action See an authorized Onan service representative LOSS OF AC VOLTAGE SENSE CODE NO 27 Control Logic The generator set Controller lost VAC sensing during normal voltage regulation when the field was functioning normally and frequency was at least 40 Hz Corrective Action See an authorized Onan service representative HIGH BATTERY VOLTAGE CODE NO 29 Control Logic During startup the generator set Controller sensed that battery system voltage was greater than 19 2 volts Corrective Action 1 Check battery bank connections and reconnect if necessary for 12 volts 2 Select a lower battery booster charge rate CONTROL CARD FAILURE EE CODE NO 35 Control Logic During startup the generator set Controller detected a EE memory error Corrective Action See an authorized Onan service representative 5 7 TABLE 5 1
20. Operator Manual Cummins Onan Performance you rely on Generator Set MDKBH Spec A D English Original Instructions 2 2010 981 0180 Issue 3 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Table of Contents SECTION PAGE Tabl O CONE reser ee ee i SARE ERE CAUMONG spear reer 5 I cee eee eee ii IMINIRODUCTION EE k wn T 1 1 AboutithnisiManua K a JF 5 Joo 1 1 Modelldentiticationkies 1 V RRR 1 1 POWAOVODIGINESORVICGs TE Vl A 1 2 EMISsionstEaDel__ 22 M 1 2 MOISEMY EA TR gene en N ee 1 2 electromagnetic compatibility 2ssssssssaaaknakakakasaaaaaaa 1 3 build standa dSh AM ee asas 1 3 2 OPERATOR CONTROL PANELS 2 cece eee ene eee eens 2 1 ocal SOM ee ene eee ene eee eee nee e eens 2 1 Rebels Coho ra 2 1 SJE OY PIE ace oe 2 2 Sp QPS UION PETET EEE EE e o aaaea 3 1 Pe a ere er en A E E ee eae ee ee 3 1 h eee meer armen eee 3 1 Engine GCoolanS FFF EEE EFE EEE gen ee tc aie ie E eter yee cern Recker 3 2 Batteries aae TT tes EFF F FT TT E TT 3 2 Fire Extinguisher POA A 3 2 Bre StardGnecksPF FEFFE FEE ares eae aceite N 3 3 Priming the FueliSyvsten Fj a om od eee os VET TN 3 3 Startingithe Generator SSA YT F TF EV V VV VVV V V VVV VT TF HITI TIT 3 3 Stoppirigethie
21. TER IN K HOSE BARB TO CONNECT o A _ O Z a x H gt faa W gt Q O W x He o Q O x O W zZ L He o Q o PRESSURE CAP amp RAW WATER FLOW SENSOR HEAT EXCHANGER CLEANOUT COVER THERMOSTAT HOUSING COOLANT PUMP BLOCK DRAIN CAP RAW WATER PUMP COOLANT amp gt RAW WATER gt FIGURE 4 4 ENGINE COOLING SYSTEM 4 9 Replacing the Thermostat Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable from the battery to prevent the engine from starting Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or removing the drain cap See Table 4 1 for scheduled replacement Refer ring to Figure 4 5 replace the thermostat as follows 1 Disconnect the negative cable at the battery to prevent the engine from starting let the en gine cool and remove the top access door and pressure cap Remove the two thermostat housing bolts and pull off the housing thermostat and gasket The hose does not need to come off Clean off the gasket area and install the new thermostat and gasket Apply Three Bond 1215 liquid sealant or equivalent to the top side of the gasket Replenish any lost coolant secure the pres sure cap secure the access door and recon nect the battery cables negative last Siphon Break Bypassing a siphon break or failing to maintain it c
22. TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting UNKNOWN SHUTDOWN CODE NO 36 Control Logic The generator set Controller declared this fault because engine speed fell below 1000 RPM for 0 5 seconds though not by generator set or engine control action Corrective Action 1 Check for mechanical damage and service as necessary 2 Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners 3 Check fuel level and refill as necessary Note The generator set fuel pickups are probably higher than the propulsion engine fuel pickups Remove combustion air or exhaust system blockages Prime the engine fuel system for at least 30 seconds p 3 3 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Replace the fuel filters and reprime p 4 6 INVALID GENSET CONFIGURATION CODE NO 37 Control Logic The generator set Controller is not configured properly
23. a pressurized closed loop liquid cooling system in which coolant is pumped through passages in the engine block head and ex haust manifold Figure 4 4 The exhaust manifold also serves as the engine coolant reservoir The heat exchanger is mounted inside the exhaust manifold Raw water the flotation water is pumped through tubes in the heat exchanger to cool the en gine coolant The raw water then passes through a hose into the exhaust water mixer where it cools the exhaust gases and is expelled The V belt drives the coolant and the raw water pumps Recommended Coolant Mixture See ENGINE COOLANT p 3 2 for recommenda tions Replenishing Normal Coolant Loss Check coolant level in the recovery tank before the first startup of each day and if necessary refill to COLD when the engine is cold or to HOT when it is running The recovery tank is designed to maintain coolant level not to fill the system If the tank is empty check for and repair any coolant leaks and refill the system through the fill neck on the engine Make sure the two hoses from the recovery tank are routed through the two holes in the right end of the generator set enclosure that the coolant recovery hose is connected to the fill neck on the engine and that the overflow hose terminates in the drip pan where it will not splash coolant on electrical compo nents Pressure Cap Let the engine cool down before re moving the coolant pressure cap or openin
24. ads such as air conditioners Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines Remove combustion air or exhaust system blockages 4 Prime the engine fuel system for at least 30 seconds p 3 3 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Air bubbles can disrupt frequency Replace the fuel filters and reprime p 4 6 GOVERNOR OVERLOAD CODE NO 22 Control Logic Maximum allowable time at full duty cycle was exceeded Corrective Action 1 Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines Remove combustion air or exhaust system blockages Prime the engine fuel system for at least 30 seconds p 3 3 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Replace the fuel filters and reprime p 4 6 FAULTY OIL PRESSURE SENDER CODE NO 23 Control Logic Controller sensed grounded sender Corrective Action See an authorized Onan service representative 5 6 TABLE 5 1 TROUB
25. an lead to engine flooding and damage to the engine not covered under War ranty See Table 4 1 for scheduled maintenance A siphon break is installed when the exhaust water mixer is below the water line If of a spring loaded valve de sign check for free movement of the plunger Re place the device if the plunger does not move freely or the body is encrusted with deposits from leakage past the valve seat If of the bleed vent type check that the vent hose is properly connected on both ends If the vent is connected to a through hull fit ting check for normal water flow whenever the en gine is running See the Installation Manual for more information regarding siphon break installation 4 10 THERMOSTAT FIGURE 4 5 TYPICAL THERMOSTAT 5 Troubleshooting To troubleshoot the generator set use TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS in conjunction with the e Series Digital Dis play or blinking of the control switch status lamp Perform the step by step corrective actions sug gested If you are still unable to resolve the problem contact an authorized Onan service representative See How to Obtain Service p 1 2 Note Many generator set shutdowns can be avoided by performing periodic maintenance on schedule TABLE 4 1 PERIODIC MAINTENANCE SCHEDULE and by not running the generator set out of fuel Note that when generator sets and propulsion engines draw from the same fuel tanks the fuel dip tubes are us
26. any loads as possible and reset the circuit break er If the circuit breaker trips right away either the electrical distribution system has a short or the cir cuit breaker is faulty Call a qualified electrician If the circuit breaker does not trip reconnect loads one by one up to a total load that does not overload the generator set or cause the circuit breaker to trip The circuit probably has a short if the circuit breaker trips right away when it is connected Electrical equipment must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short circuits occur Short circuits in electrical equip ment can cause fire and electrical shock leading to severe personal injury or death Electrical equipment and its grounding must be main tained properly to protect against short circuits 3 5 COLD TEMPERATURE OPERATION Drain the heat exchanger See Service Manual and muffler before cold weather sets in if the generator set is not being used Freezing water can damage the muffler and the raw water tubes in the heat ex changer CARE OF NEW OR RE BUILT ENGINE Avoid no load operation as much as possible during break in Change the oil and oil filter after the first 50 hours of operation p 4 5 EXERCISING THE GENERATOR SET Exercise the generator set at least 1 hour every month if use is infrequent Run the generator set at 1 4 to 3 4 load A single exercise period is better
27. ater supplies e Ingestion Toxic by ingestion If swallowed induce vomit ing only under the advice of a Doctor or poison control centre Delayed treatment may result in fatality e Inhalation of vapour Remove from further exposure In case of ir riatation to lungs or throat seek medical ad vice e Aspriation inhalation of liquid Obtain immediate medical assistance e Eyes Flush copiously with water or preferable eye wash solution for at least fifteen minutes Seek medical advice e Skin Wash thoroughly with soap and water and seek medical attention if irritation develops Change clothing if necessary and wash before re use e Spillage Soak up using an absorbent material and dis pose of this as directed under Storage Trans port GAS OIL This product is also known as Red Diesel Fuel Oil and type A1 or A2 It can be pale red or a clear liquid with a characteristic mild odour It contains catalyti cally cracked oil petroleum distillates quinizarin and gas oil maker dye red The catalytically cracked oil and petroleum distillates are potentially hazard ous constituents The substance has an initial boiling point of 180 C a flash point greater than 56 C and a vapour pres sure less than 0 7mm Hg at 20 C and has negligible solubility in water It is used as a fuel for off road diesel powered ve hicles and stationary engines and can be found in fuel tanks pipes and injection systems The sub stanc
28. contact and breathing of vapors Use rub ber gloves and wash exposed skin Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the generator set before re moving the oil fill plug 1 Pull the plug and dipstick out of the oil fill neck Figure 4 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 3 1 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 not dropped more than 1 3 of the way between the high and low beads A CAUTION Too little oil can cause severe engine damage Too much oil can cause high oil consumption 3 Secure the oil fill plug which snaps into its socket 4 4 OIL FILL NECK WITH PLUG AND ATTACHED DIPSTICK KEEP OIL LEVEL BETWEEN THESE TWO BEADS ON DIPSTICK ee FIGURE 4 1 OIL FILL NECK AND DIPSTICK CHANGING ENGINE OIL AND FILTER Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent the engine from starting State a
29. d is insol uble in cold water It is used in engine lubricant oil systems sump pan and filters make up tanks and piping systems as a lubrication oil for use in wide range of diesel en gines operating under severe conditions Installers operators and maintainers are likely to encounter this product HAZARDOUS REACTIONS This product is stable although slightly re active with oxidising agents Results of decomposition are carbon oxides CO COs and water Although harmful if swallowed or aspirated breathed in repeated or prolonged exposure is not known to aggravate medical conditions Used oil may contain harmful combustion by prod ucts and unburnt fuel that will cause skin reactions as detailed for fuel Particular care must be taken if oil form a severely overheated engine is handled use impervious gloves lab coat and safety glasses Do not breathe vapour spray PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Adopt a high standard of personal hygiene In case of skin contact wash thoroughly with soap and wa ter Use safety glasses impervious gloves and lab coat Avoid contamination inside the gloves If overalls become contaminated discontinue use and clean thoroughly No special respiratory precautions are necessary in normal use Do no breathe vapour spray when handling hot materials STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers ti
30. d outlet openings are not clogged with debris or blocked Keep the generator set compartment clean MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or in light switches or other equipment and flames or sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch work light ON or OFF away from battery Stop generator set and disconnect charger before disconnecting battery cables Disconnect negative cable first and reconnect last Refer to Table 4 1 for scheduled battery mainte nance and follow the battery manufacturer s in structions Have the battery charging system ser 4 3 viced if DC system voltage is consistently low or high Check the battery terminals for clean tight connec tions Loose or corroded connections have high electrical resistance which makes starting harder Always 1 Keep the battery case and terminals clean and dry and the terminals tight Use a battery terminal puller if the battery has terminal posts Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing CHECKING ENGINE OIL LEVEL State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin
31. d to be drained or replaced Draining Water and Sediment Drain water and sediment more often than sched uled Table 4 1 if fuel quality is poor or condensa tion cannot be avoided 1 Disconnect the negative cable at the battery to prevent the engine from starting and close any fuel supply and return valves 2 Open the front access door and drain the filter about 1 2 cup 120 ml into a suitable contain er by removing the drain plug bottom of filter 3 Re install the drain plug and dispose of the drain off in accordance with local environmen tal regulations Replacing Fuel Filter See Table 4 1 for scheduled filter change Change the filter if the engine lacks power 1 Disconnect the negative cable at the battery to prevent the engine from starting and close any fuel supply and return valves 2 Open the front access door and spin off the old filter with a filter wrench and dispose of it in ac cordance with local environmental regulations 3 Clean the contact surface on the filter base lu bricate the new filter gasket and spin the new filter on hand tight 4 Prime the engine for at least 30 seconds Page 3 3 to fill the new filter Run the genera tor set and check for leaks Tighten the filter by hand if necessary FILTER FIGURE 4 3 FUEL FILTER MAINTAINING THE ENGINE COOLING SYSTEM Refer to Table 4 1 for scheduled maintenance Cooling System Overview The engine is cooled by
32. e should not be used for any other purpose without contacting the manufacturer or supplier In stallers operators and maintainers are likely to en counter this substance HAZARDOUS REACTIONS This liquid is flammable Avoid smoking heat sources such as welding and naked flames sparks and static electricity build up Thermal de composition products are hazardous containing COx NOx and SOx compounds The vapour is explosive High vapour concentra tions can cause respiratory irritation dizziness nausea and loss of consciousness Excessive and prolonged exposure to the mist can cause chronic inflammatory reaction of the lungs and a form of pulmonary fibrosis vi Avoid strong oxidising agents e g chlorates which may be use in agriculture Gas oil is slightly irritating to the skin and has a de fatting action Toxicity following single exposure to high level of gas oil is of low order Prolonged re peated skin contact may de fat the skin resulting in possible skin irritation and dermatitis In some cases warty cancerous growths have occurred PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Observance of good housekeeping rules will en sure general safety Do not smoke Avoid breathing mist When working on or testing injection equipment special care is required to avoid perforation of skin by high pressure fuel Use eye protection in the event of suspected high pressure leak Adopt a hig
33. e the water line fill the strainer with water to assist priming Check for and reconnect or replace any disconnected kinked or leaking raw water hoses 4 Inspect the siphon break if provided for proper operation EXTERNAL SHUTDOWN CODE NO 61 Control Logic The generator set was shut down by a fire suppression system or other external control Corrective Action Make all necessary repairs to the generator set and connected equipment and reset the external control which shut down the generator set 5 10 6 Specifications GENERATOR 2 Bearing 2 Pole Rotating Field Microprocessor Regulated Rating on Generator Set Nameplate FUEL CONSUMPTION 60 Hz Full Load 0 55 gph 2 1 liter hr Half Load 0 35 gph 1 3 liter hr 50 Hz Full Load 0 44 gph 1 7 liter hr Half Load 0 28 gph 1 0 liter hr Engine Generator Speed 60 Hz 2900 3600 rpm 50 Hz 2400 3000 rpm ENGINE 4 Stroke Cycle Indirect Injection Diesel Water Cooled Microprocessor Governed Isochronous Number of Cylinders 2 Bore 2 64 inch 67 mm Stroke 2 68 inch 68 mm Displacement 29 23 inch 479 cm3 Compression Ratio 23 5 1 Firing Order Clockwise Rotation 1 2 Fuel Injection Timing 18 25 19 75 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
34. el add or drain oil as necessary and repair any leaks p 4 4 SERVICE CHECK CODE NO 3 Control Logic A fault with a 2 Digit Fault Code Number occurred Corrective Action Check the 2 Digit fault code by Pushing and Releasing Stop The 2 Digit fault will be one of the following in this table Does not apply to e Series Digital Display 5 3 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting OVERCRANK CODE NO 4 Control Logic Cranking time exceeded 20 to 60 seconds depending on ambient temperature Corrective Action 1 Push the generator set line circuit breaker OFF 2 Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines Remove combustion air or exhaust system blockages Open any closed fuel supply and return valves Prime the engine fuel system for at least 30 seconds p 3 3 Service the batter
35. engine from starting NO RESPONSE AT OPERATOR PANEL OR CONTROL SWITCH Possible Cause Faulty switch poor or missing connections dead battery Corrective Action 1 Push the Emergency Stop Breaker ON if tripped 2 Try the Operator Panel or control switch on the generator set local if there is no response at a remote Operator Panel or control switch and vice versa 3 If none of the Operator Panels or control switches works service as necessary by cleaning and tighten ing battery connections recharging or replacing the battery or replacing damaged battery cables p 4 3 THE STARTER ENGAGES AND DISENGAGES Possible Cause Low cranking voltage Corrective Action 1 Push the generator set line circuit breaker OFF 2 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4 3 THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE Possible Cause Marginal battery battery connections or charging system Corrective Action 1 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4 3 2 Check for and disconnect parasitic battery loads NO AC POWER WHEN GENERATOR SET IS RUNNING Possible Cause A Circuit Breaker is OFF tripped or malfunctioning or the generator is not connected prop erly Corrective Action 1 Reset or turn ON the generator
36. et Installation Manual PRE START CHECKS Before the first start of the day and after every eight hours of operation inspect the generator set as instructed under GENERAL INSPECTION p 4 2 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Re turning the generator set to Service p 3 6 if the boat has been in storage Before each start 1 Make sure all CO detectors on board are work ing properly 2 Check for swimmers that might be exposed to the engine exhaust 3 Disconnect all electrical loads PRIMING THE FUEL SYSTEM The fuel system should be primed after replacing the fuel filter or running the generator set out of fuel To prime the fuel system Push and Hold STOP on the e Series Digital Display or STOP Prime on the control switch for at least 30 seconds 3 3 STARTING THE GENERATOR SET The generator set can be started and stopped from the generator set control panel or remote control panel 1 Visually inspect for water coolant fuel and ex haust leaks Do not start the generator set if there is a leak Repair fuel leaks immediately Push and Hold START on the e Series Digital Display or control switch until the generator set starts The generator set status lamp blinks when the engine is cranking and comes on and stays on when the generator set starts and runs The status displayed on the e Series Digi tal Display changes from Starting to Running Figure 2
37. g the coolant drain Hot coolant under pressure can spray and caus severe burns Wear safety glasses Replace the pressure cap every two years seals deteriorate and leak Proper cooling system pres 4 7 sure 10 psi is essential for optimal engine cooling and minimal coolant loss Coolant Hoses Engine components drains filters hoses etc will be hot and can cause server burns The use of protective gloves is recom mended Check for hoses that leak or are damaged Have a qualified service person replace any leaking or damaged hoses Draining and Cleaning Cooling System Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable from the battery to prevent the engine from starting Let the engine cool down before re moving the coolant pressure cap or opening the coolant drain Hot coolant under pressure can Spray and cause severe burns Wear safety glases Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended 1 Have towels and containers ready to wipe up collect and properly dispose of the coolant Disconnect the negative cable at the battery to prevent the engine from starting let the en gine cool and remove the front and top access doors and the coolant pressure cap Drain the exhaust manifold coolant reservoir by disconnecting the hose at the coolant pump inlet Fi
38. ghtly sealed when not in use Keep in a cool well ventilated area out of sun light and away from naked flames Store well away from food stuffs and drinking water Wear splash goggles full suit boots and gloves Absorb leak spill with an inert material and dispose of unwanted or absorbed substance through an au thorised contractor to a licensed site Finish clean ing by spreading water on the contaminated sur face and allow to evacuate through the sanitary system EMERGENCY ACTION e Fire Extinguishing media Large fire Use water spray fog or foam Do not use water jet Small fire Use dry chemical powder or COs Fire fighters to use self contained breathing apparatus and full turnout gear Keep fire ex posed containers cool e Inhalation of vapour Remove from further exposure Obtain medi cal attention viii Aspiration inhalation of liquid Obtain immediate medical assistance Eyes Flush copiously with water or preferably eye wash solution for at least fifteen minutes Ob tain medical advice Skin Wash thoroughly with soap and water Obtain medical advice if irritation develops Change clothing if necessary and wash before re use Spillage Absorb with an inert material and dispose of this as directed under Storage Transport Ingestion Do not induce vomiting Obtain medical advice immediately Generator Set Warning Labels Warning signs are provided on the generator set at or near the point
39. gure 4 4 and twisting it down into a container Drain the block by removing the cap on the drain fitting on the left side of the block Fig ure 4 4 Use an 11 16 inch socket on a swivel and 12 to 18 inch extension To catch the cool ant and direct it into a container insert the sock et and extension through a piece of hose large enough to fit over the socket but shorter than the extension The hose will catch the coolant as the cap is being unscrewed Use radiator cleaning chemicals to clean and flush the cooling system before refilling with fresh coolant Follow the cleaner manufactur er s instructions 2 Refilling Cooling System Low coolant level can cause severe engine damage Make sure the system is full Filling a hot engine with cold water can cause cracks in the manifold head and block 4 8 Close the block drain cap and reconnect the pump inlet hose and fill the system through the engine fill neck The system will fill only as fast as the air can escape Fill to the bottom of the fill neck Start and run the engine for a couple of minutes to dislodge air pockets and shut it down Add as much coolant as necessary and secure the pressure cap Then refill the recovery tank up to the COLD mark EXHAUST COOLANT RESERVOIR COULD BE CONNECTED TO EXTERNAL SIPHON BREAK AT THIS POINT SEE INSTALLATION MANUAL EXHAUST WATER MIXER WITH HIGH TEMPERATURE EXHAUST SWITCH EXHAUST amp RAW WATER OUT RAW WA
40. h er parts Replace worn or damaged fuel line parts before leaks occur Replace hose with with USCG TYPE A1 or ISO 7840 A1 fuel hose Prime the fuel system if the generator set ran out of fuel 4 2 Coolant Level Check coolant level in the recovery tank and if nec essary refill to COLD when the engine is cold or to HOT when it is at normal running temperature The recovery tank is designed to maintain coolant level not to fill the system If the tank is empty check for and repair any coolant leaks and refill the system through the fill neck on the engine See Refilling the Cooling System p 4 8 Use the recommended antifreeze mixture p 3 2 Raw Water System Clean out the sea water strainer if necessary and make sure the sea cock is open for generator set op eration Also when a water exhaust separator is provided see Installation Manual open the sea cock for the water drain hose Check for hoses that leak or are damaged Have a qualified service person replace any leaking or damaged hoses Battery Connections See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Mechanical Monitor generator set status using the e Series Dig ital Display p 2 3 Visually inspect genset for mechanical damage For generator sets with a sound shield install service doors before running the generator set to listen for unusual noise Check the generator set mounting bolts Check to see that the generator set air inlet an
41. h standard of personal hygiene In the case of skin contact wash well with soap and water Use glove and overalls and eye protection goggles if there is a risk of splashing Use oil impervious gloves and avoid contamination inside the gloves If overalls become contaminated discontinue use and clean thoroughly Contaminated clothing should be removed soaked with water and laun dered before re use No special respiratory precautions are necessary in normal use DO NOT use as a solvent for removing dirt grease etc from skin STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight and away from naked flames Electrical continuity is required between the transport and storage vessels during product trans fer Contain leak spill with sand earth or other suitable material and prevent entry of substance into drain age sewerage system water courses and land Dispose of unwanted or absorbed substance through an authorised contractor to a licensed site Inform local and fire authorities should the product reach waterways drains etc EMERGENCY ACTION e Fire Extinguishing media Large fire Foam water fog Never use water jet Small fire foam dry powder AAAF COs sand earth Avoid making sparks Fire fighters to use self contained breathing apparatus Keep fire ex posed containers cool using water fog spray Prevent run off f
42. ile the generator set is run ning PRE ALARM This status lamp amber comes on when an engine Pre Alarm condition exists p 2 5 ALARM This status lamp red blinks during fault shutdown p 2 4 2 2 e ____ GENSET PRE ALARM O ALARM STOP START O FIGURE 2 2 REMOTE OPERATOR PANEL Genset Status Screens Generator set status is displayed on 3 screen pages Figure 2 3 GEN STATUS PG1 appears when the Display is turned on Press the double arrows F to toggle between the 3 screen pages The Status line on PG1 will display the word Prim ing Starting Running Stopped or Volt Adj The rest of the lines on the 3 status screen pages display AC output voltage AC frequency engine coolant tem perature engine oil pressure starting battery volt age and total generator set running time GEN STATUS Pgl Status Starting AC Volts 120V AC Freq 60Hz ETUP FAULTISCREE CEN SVF Cool Temp 123F c oO O H Oil Press S H ETUP FAULTISCREE TUS g3 Batt Volt 12 5V Hr Meter 12345 6 ETUP FAULT SCREE TO FIGURE 2 3 TYPICAL GENERATOR SET STATUS SCREENS 2 3 Fault Screens If a fault shutdown occurs the ALARM status lamp will blink and the LCD screen will display the Fault Number a description of the Fault and the hour i
43. king on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles ENGINE EXHAUST IS DEADLY Never sleep in the boat while the generator set is running unless the boat is equipped with properly working carbon monoxide detectors The exhaust system must be installed in accor dance with the generator set Installation Manual and be free of leaks Make sure the bilge is adequately ventilated with a power exhauster Inspect for exhaust leaks every startup and af ter every eight hours of operation For more information about carbon monoxide see American Boat and Yacht Council ABYC publication TH 22 Educational Information About Carbon Monoxide DIESEL FUEL IS COMBUSTIBLE e Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flames sparks pilot lights arc producing equipment and all other sources of ignition well away e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring GASOLINE IS FLAMMABLE AND EXPLOSIVE e Because this generator set is an Ignition Pro tected device no substitutes are permitted for the parts listed in the Critical Parts Index of the generator set Parts Catalog They must be purchased from Onan and be installed in ac cordance with the generator
44. l dose for humans re ported to be 100ml PROTECTIVE MEASURES Refrain from eating drinking or smoking when us ing the product Adopt a high standard of personal hygiene In case of skin contact wash immediately with soap and water Ensure good ventilation and avoid heat sources Avoid breathing mist if ther is a risk of vapour or particulate use a suitable organic vapour mask Eye protection gloves overalls impervious apron should be used Avoid contaminated discontinue use and clean throughly STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight away for naked flames and strong acids do not freeze Store well away from food stuffs and drinking water Take special care to avoid discharge into drains sewers and wa ter courses Contain leak spill with sand earth or non combus tible absorbent material to prevent entry of sub stance into drainage sewerage system water courses and land Eliminate all ignition sources use plastic shovel to transfer to suitable container and dispose of unwanted or absorbed substance through and authorised contractor to a licensed site EMERGENCY ACTION e Fire Extinguishing media COs alcohol resistant foam dry powder or water spray Fire fighters to sue self contained breathing apparatus Keep fire exposed containers cool Prevent run off from entering waterways drains and drinking w
45. n total generator set running time when the Fault oc curred Figure 2 4 Refer to TABLE 5 1 TROU BLESHOOTING GENSET FAULTS to diagnose and correct the problem The e Series Digital Display will display the fault in definitely Touch any button to clear the fault The display will turn off in 5 minutes after the fault has been cleared Press 4BACK to go back to the GEN STATUS screen 2 4 FAULT Speed Sense Lost Fault No 45 Hour 10000 1 BACK HIST FIGURE 2 4 TYPICAL FAULT SCREEN Displaying Last 5 Faults To display any of the last five faults press the FAULT button on any GEN STATUS screen Then press the HIST button on the FAULT screen Figure 2 5 The FAULT HISTORY screen will display the last Fault Number a description of the Fault and the hour in total generator set running time when the fault occurred Press the double arrows F42 to toggle between the last 5 faults If there are no faults the FAULT HISTORY screen will display No Stored Faults Press 4BACK to go back to GEN STATUS Engine Pre Alarm Screens The PRE ALARM status lamp will start to blink when engine oil pressure or temperature ap proaches its limit for engine shutdown The Display will display Low Oil Pressure or High Engine Tem perature on the PRE ALARM screen Figure 2 6 Press 4BACK to go back to GEN STATUS to moni tor the engine temperature or oil pressure Service the generator set as required FROM FAULT
46. nd federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rub ber gloves and wash exposed skin Crankcase pressure can blow hot engine oil out the fill opening causing severe burns Always stop the generator set before re moving the oil fill plug Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Refer to Table 4 1 for scheduled engine oil change 1 Run the generator set under load until it is up to operating temperature stop it and disconnect the negative battery cable at the battery 2 Remove the oil fill plug Figure 4 1 open the front access door and drain the engine oil into a container by opening the drain valve Fig ure 4 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 follow the instructions provided 3 Close the oil drain valve 4 Spin off the old oil filter with a filter wrench and wipe off the filter mounting surface A filter wrench is available from Onan Remove the old gasket if it does not come off with the filter 5 Apply a film of oil to the filter gasket and partly fill the filter with oil so that it reaches engine 4 5 parts sooner at startup Spin the new filter on by hand until the gasket just touches the moun
47. nk Pressing Stop again will stop the blinking The two digit code consists of 1 to 7 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the second set of blinks the units digit of the shutdown code number For example Shut Down Code No 36 appears as blink blink blink pause blink blink blink blink blink blink long pause repeat e Four blinks indicate shutdown due to a failure to start within the time allowed for cranking e Five blinks indicate shutdown due to high lev els of Carbon Monoxide CO in the vessel e Seven blinks indicate shutdown due to a loss of raw water flow for engine and exhaust cool ing The fault code stops blinking after five minutes Press Stop three times within three seconds to re store fault code blinking Note The last fault logged will blink even though the condition that caused the shutdown may have been corrected TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set 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
48. of risk To avoid injury always take the necessary precautions as indicated on the sample signs shown below Caution Warning Indicates a risk of personal injury Caution Warning of Temperature Hazard Indicates a risk of personal injury from high temperature Caution Warning of High Voltage Hazard Indicates a risk of personal injury from electric shock electrocution Caution Warning of Engine Coolant Pressure Hazard Indicates a risk of personal injury from hot pressurized engine coolant Caution Warning Indicates to read Operator manual for additional information Caution Warning of No Step Indicates a risk of personal injury or equipment damage from stepping on equipment Caution Warning of Combustion Explosion Hazard Indicates a risk of personal injury from explosion Caution Warning of Belt and Rotating Part Hazard Indicates a risk of personal injury from entanglement in moving parts Caution Warning of Chemical ingestion burn Hazard Indicates a risk of personal injury or asphyxiation from poisonous fumes or toxic gases Caution Warning of High Voltage or Current Source Hazard Indicates a risk of personal injury from electrical shock electrocution 1 Introduction ABOUT THIS MANUAL This is the Operator Manual for the generator sets listed on the front cover Each operator should study this manual carefully and observe all of its instruc
49. one 1 763 574 5000 Toll free 1 800 888 6626 Fax 1 763 574 5298 Email www cumminsonan com contact www cumminsonan com Cummins Onan the C logo and Performance you rely on are trademarks of Cummins Inc 2010 Cummins Power Generation Inc All rights reserved
50. ons 3 status lamps a START but ton and a STOP button Figure 2 2 Turning On the Display Touch any button to turn on the Display which will initialize and attempt to establish communications with the generator set controller All connected Op erator Panels will turn on automatically when the generator set is started at any station They will all turn off 5 minutes after the generator set has re ceived a normal command to stop They will stay on indefinitely until a fault shutdown is cleared by touching any button on any Operator Panel Start Button Starting the Generator Set Push and Hold START until the generator set starts The GENSET status lamp blinks while the engine is cranking It comes on when the generator set starts and stays on while it runs The status displayed on the LCD changes from Starting to Running Figure 2 3 See STARTING THE GENSET p 3 3 Stop Button Stopping the Generator Set Push and Release STOP The GENSET status lamp will go out The status displayed on the LCD will change from Run ning to Stopped Figure 2 3 See STOPPING THE GENSET p 3 3 Priming the Fuel System Push and Hold STOP The GENSET status lamp will blink The status dis played on the LCD will change to Priming in 2 sec onds Figure 2 3 See PRIMING THE FUEL SYS TEM p 3 3 Genset Status Lamps GENSET This status lamp green blinks while the engine is cranking or the fuel system is being primed It stays on wh
51. ot be run with the service doors removed missing e Engine components can be hot and cause se vere burns Hot coolant under pressure can spray and cause severe burns e Use personal protective equipment when maintaining or installing the generator set such as gloves saftey glasses etc THE HAZARDS OF CARBON MONOXIDE Engine driven generators can produce harmful level of carbon monoxide that can injuire or kill you The nature of boating is such that you can be harmed by this poisonous gas despite good ge neartor set maintenance and proper ventilation ONLY YOU CAN PROTECT YOURSELF FROM CO POISONING Watch constantly for swimmers when the gen erator set is running Make sure exhaust cannot get under the deck between hulls or enter the living quarters through a window vent or door Make sure all CO detectors and audible alarms are working properly Pay attention to the signs of CO poisoning Check the exhaust system for corrosion ob struction and leaks each time you start the generator set and every eight hours if you run it continuously GENERATOR VOLTAGE IS DEADLY Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes Interconnecting the generator set and shore power can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent interconnections Use caution when wor
52. ping the generator set Check for loss of coolant af ter every emergency stop of fault shut down Refill and clean up as necessary EMERGENCY STOP Push the EMERGENCY STOP SWITCH to OFF p 2 1 After all necessary repairs have been made push the switch to ON so that the generator set can be operated LOADING THE GENERATOR SET How much equipment load can be powered de pends upon the generator set power rating The generator set will shut down or its AC output circuit breakers will trip if the sum of the loads exceeds generator set power or circuit breaker rating To avoid overloading the generator set and causing shutdowns compare the sum of the loads of the ap pliances that are likely to be used at the same time with the power rating of the generator set Use Table 3 1 or the ratings on the appliances them selves to obtain the individual appliance loads If the appliance is marked in amps and volts only multiply the amps times the volts to obtain the appliance load watts It may be necessary to run fewer ap pliances at the same time the sum of the loads must not be greater than generator set rating The generator set may shut down due to overload when a large motor or air conditioner is started or cycles off and then on again even though the sum of the loads is less than generator set rating The rea son for this is that a motor s startup load is much larger than its running load It may be necessary to run fewer
53. pment Keep flames sparks pilot flames electrical arcs and switches and all other sources of ignition well away Keep a multi class ABC fire extinguisher handy High quality Grade 2 D diesel fuel is necessary for good performance and long engine life Diesel fuels specified by EN 590 or ASTM D975 are recom mended Use Grade 1 D diesel fuel if the fuel tank is exposed to temperatures below 40 F 5 C 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 tempera tures use fuel that has a cloud point temperature at which wax crystals begin to form at least 10 F 6 C degrees below the lowest expected fuel tem perature Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM D6078 or maxi mum scar diameter of 0 45 mm as measured by ASTM D6079 or ISO 12156 1 ENGINE OIL Use API American Petroleum Institute Service Category CI 4 engine oil or better Also look for the SAE Society of Automotive Engineers viscosity grade Referring to Figure 3 1 choose the viscosity grade appropriate for the ambient temperatures ex pected until the next scheduled oil change Multi grade oils such as SAE 15W 40 are recommended for year round use 3 1 15W40 Lal 10W40 fe o ts Cn fe o ts Cn 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 0 OC 34 29 23 18 12 7 4 4 10 16 21 2
54. requency Replace the fuel filters and reprime p 4 6 HIGH AC FREQUENCY CODE NO 14 Control Logic After the starter was engaged Frequency jumped to more than 70 Hz for 40 milliseconds or to more than 2percent over nominal for 6 seconds Corrective Action 1 Check for a tripped generator set circuit breaker reset it if necessary and run with fewer connected loads A breaker tripping under load can cause generator set frequency to overshoot 2 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Air bubbles can disrupt frequency 5 5 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting LOW AC FREQUENCY CODE NO 15 Control Logic During normal operation Frequency fell to less than 90percent of nominal for more than 8 seconds Corrective Action Push the generator set line circuit breaker OFF If the generator set now runs reduce the number of loads especially those with high motor starting lo
55. riate containters for transport storage and disposal of waste sub stances Follow local regulations for disposal and recycling ANTIFREEZE FLEETGUARD ES COMPLEAT EG PREMIX This antifreeze is also known as an ethylene glycol based coolant summer coolant coolant additive It is purple coloured viscous liquid with a mild chemi cal odour is soluble in water and harmful It con tains ethylene gylcol and diethylene glycol Ethyl ene glycol is a potentially hazardous consituent The substance has a boiling point of 107 C anda flash point of 121 C It is used as an engine coolant additive and can be found in the engine cooling systems and heat ex changers Installers operators and maintainers ar likely to encounter this substance HAZARDOUS REACTIONS Ethylene glycol is combustible when exposed to heat or flame and can react vigorously with oxi dants Moderate explosive hazard in form of vapour when exposed to heat or flame Hazardous prod ucts resulting from combustion or decomposition include carbon monoxide carbon dioxide and acrid smoke Self contained breathing apparatus must be worn in the event of fume build up Avoid strong oxidizing agents incompatible with sufuric acid nitric acid caustics and aliphatic amines It may cause neurological signs and sysmptoms and kidney damage It is also a skin and eye irritant Very toxic in particulate form upon inhalation M 11 Harmful if swallowed letha
56. rom entering waterway drains and drinking water supplies e Ingestion Do not induce vomiting Wash the mouth out with water and send to hospital immediately e Inhalation of vapour Remove from further exposure Obtain medi cal assistance immediately e Aspiration inhalation of liquid If following ingestion of gas oil vomiting oc curs there is danger of aspiration into the lungs This would cause intense local irritation and chemical pneumonitis that can be fatal Obtain immediate medical assistance e Eyes Irrigate copiously with water or preferably eye wash solution for at least five minutes If irrita tion persists seek medical advice e Skin Wash thoroughly with soap and water Change clothing if necessary If high pressure injection has occurred prompt surgical attention is required e Spillage Absorb using sand earth or other suitable ma terial Dispose of unwanted or absorbed flam mable material as directed under Storage Transport LUBRICATION OIL PREMIUM BLUE E 15W40 Also known as oil lube oil sump oil new oil is dark viscous liquid with a slight characteristic odour The base oil contains distillates petroleum sol vent dewaxed heavy paraffinic It is not classified as dangerous according to Directive 1999 45 EC and its amendments and is not classified accord ing to the EU regulations vii It has a boiling point greater than 150 C a flash point Open Cup of 220 C Cleveland an
57. s on the human body Safety of machinery Human body dimensions Part 1 Principles of determining the dimensions re quired for openings for whole body access into ma chinery Safety of machinery Human body dimensions Part 2 Principles for determining the dimensions re quired for access openings Safety of machinery Human body dimensions Part 3 Anthropomorphic data Safety of machinery Electrical equipment of ma chines General requirements Safety of machinery Ergonomic design principles Terminology and general principles Safety of machinery Guards General require ments for the design and construction of fixed and movable guards Safety of machinery Basic concepts general prin ciples for design Basic terminology methodology Safety of machinery Basic concepts general prin ciples for design Technical principles Ergonomics of the thermal environment Methods for the assessment of human responses to contact with surfaces Hot surfaces 1 3 Safety of machinery Safety related parts of control BS EN ISO 13849 1 2008 systems BS EN ISO 13850 2006 ae of machinery Emergency stop Principles for Safety of machinery Indication marking and actua BS EN 61310 1 2008 tion Part 1 Requirements for visual auditory and tactile signals Safety of machinery Indication marking and actua BS EN 61 ee tion Part 2 Requirements for marking Electromagnetic compatibility EMC
58. sGenerator Set ae secs oer T TIT 3 3 Emergency Stop S 3 4 Loading the Generator Set v1v1212sssansrssraaaaaaarsrraar na 3 4 No Load Operation 2sssssnnvssssssraaaaaaaaassrsaarrraa anr 3 4 Connecting to Shore Power 00 cece eee eens 3 4 Resetting Line Circuit Breakers 0 eect eee 3 5 Cold Temperature Operation 2 2 2 vvssssssaaassrraaa lakka 3 5 Care of New or Re Built Engine 2 v 222ssssanssssaaaaaaaarn i 3 5 Exercising the Generator Set 00 c cece eee eee eee 3 5 Storing the Generator Set 00 c cece eee tenes 3 6 4 PERIODIC MAINTENANCE E VE TT 4 1 Periodic Maintenance Schedule 2 0 cece eee eee eee ee 4 1 Ccieatiiches Otte ee ae on ee E 4 2 Maintaining the Battery and Battery Connections 4 3 Checkinguengime Oilbeveneees gta Tet SRmmpeMeee ree eta eae 4 4 Changiigeengimergibandueivcras Ue T 4 5 Draining Replacing the Fuel Filter 0 0 cece eee eee 4 6 Maintaining the Engine Cooling System 0 0 cece eee eee 4 7 SeIROUBEESEOOMING Tae SA a 5 1 Troubleshooting with Operator Panel 00 eect eee 5 1 Troubleshooting with Status Lamp 00 cece eee 5 1 GESPECIRICATIONSb SM ce eee ceed ee eee ee eee ar 6 1 TAMAINTENANCE RECORD ene eee eee ee eee wee es 7 1 SAFETY PRECAUTIONS Thoroughly read the OP
59. ting pad and tighten 3 4 turn Refill the engine with the proper type and amount of engine oil See ENGINE OIL REC OMMENDATIONS p 3 1 and Specifications Section 6 Check the oil level and add or drain oil as necessary ACAUTION Too little oil can cause severe engine damage Too much oil can cause high oil consumption Close the access door and dispose of the used oil and oil filter according to local environmental regulations OIL DRAIN OIL VALVE FILTER FIGURE 4 2 OIL FILTER AND DRAIN VALVE DRAINING REPLACING THE FUEL FILTER Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent the engine from starting Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning equip ment or in areas sharing ventilation with such equipment Keep flames sparks pilot flames electrical arcs and switches and all other sources of ignition well away Keep a multi class ABC fire extinguisher handy Engine components drains filters hoses etc will be hot and can cause server burns The use of protective gloves is recom mended Keep dirt water and other contaminants from enter ing the fuel system and corroding or clogging fuel in jection components The generator set has a water separator fuel filter Figure 4 3 Check for other up stream filters which may also nee
60. tive SPEED SENSE LOST CODE NO 45 Control Logic After start disconnect the generator set Controller lost speed sense quadrature zero crossings for 0 25 seconds Corrective Action See an authorized Onan service representative FIELD SENSE LOST RAM CODE NO 48 Control Logic Controller unable to sense field voltage Corrective Action See an authorized Onan service representative OVERPRIME CODE NO 57 Control Logic A local or remote control switch was held in the Prime position for more than 5 minutes Corrective Action Check for and remove any object that may be holding either control switch remote or local in the prime position 5 9 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting HIGH EXHAUST TEMPERATURE CODE NO 58 Control Logic Exhaust temperature exceeded design limits due to lack of water delivered to the exhaust water mixer Corrective Action Open the sea valve Check for and clean a blocked sea water strainer If abov
61. ts that can rust Returning the Generator Set to Service 1 Check the oil tag on the generator set and change the oil if the viscosity indicated is not appropriate for the temperatures expected See ENGINE OIL RECOMMENDATIONS p 3 1 Reconnect the starting battery negative cable last See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 4 3 Perform the maintenance required p 4 1 conduct the pre start checks and prime the fuel system Start and run the generator set Turn on the generator set line circuit breaker p 2 1 when ready to power loads 4 Periodic Maintenance PERIODIC MAINTENANCE SCHEDULE Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent starting while working on the generator set Periodic maintenance is essential for top perfor mance and long generator set life Use Table 4 1 as a guide for normal periodic maintenance Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever warranty work must be completed by an au thorized Onan service representative To help you keep generator set maintenance regu lar and provide a basis for warranty claims record maintenance performed in Maintenance Record p 7 1 TABLE 4 1 PERIODIC MAINTENANCE SCHEDULE Check Generator Bearings Drive Belt
62. ually arranged so that the generator sets run out of fuel first By marking the generator set empty points on the fuel gauges it will be easier to tell when to stop the generator sets before running them out of fuel 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 TROUBLESHOOTING WITH OPERATOR PANEL If a fault shutdown occurs the ALARM status lamp on the e Series Digital Display will blink and the LCD screen will display the Fault Number a description of the Fault and the hour in total generator set run ning time when the Fault occurred Figure 2 4 The fault will be displayed indefinitely Touch any button to clear the fault The display will turn off in 5 minutes after the fault has been cleared See Page 2 5 to display any of the last five faults in fault history 5 1 TROUBLESHOOTING WITH STATUS LAMP If a fault shutdown occurs the amber status lamp on the control switch will repeatedly blink sets of 3 4 5 or 7 blinks e One blink indicates shutdown due to high en gine temperature e Two blinks indicate shutdown due to low oil pressure e Three blinks indicate a service fault Press Stop once to cause the two digit shutdown code to bli
63. use severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting HIGH AC VOLTAGE CODE NO 12 Control Logic After voltage regulation was enabled Output Voltage jumped to more than 125percent of rated for 75 milliseconds or to more than 115percent of rated for 3 seconds Corrective Action 1 Push the generator set line circuit breaker OFF start the generator set If output voltage is normal the problem is in the circuits external to the generator set 2 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Air bubbles can disrupt frequency LOW AC VOLTAGE CODE NO 13 Control Logic After voltage regulation was enabled Output Voltage fell to less than 90percent of rated for 5 seconds Corrective Action Push the generator set line circuit breaker OFF If the generator set now runs and voltage and frequency are normal reduce the number of electrical loads Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines Remove combustion air or exhaust system blockages 4 Prime the engine fuel system for at least 30 seconds p 3 3 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Air bubbles can disrupt f
64. uts down abnormal ly this lamp will slowly blink a numerical code to indi cate the cause of shutdown See Troubleshooting Section 5 The green status lamp comes on to in dicate that the generator set is running Emergency Stop Switch In an emergency push the switch to OFF Push it to ON after all necessary repairs to the generator set and connected equipment have been made Line Circuit Breaker The line circuit breaker protects the AC power leads connected to the generator set from overloads and equipment short circuits Hour Meter The hour meter records generator set operating time in hours It cannot be reset REMOTE CONTROL Remote Control Stations The boat may be equipped with one or more remote control stations having a remote Operator Panel p 2 2 or a control switch with status lamps Boat Monitoring System The boat may be equipped to monitor generator set operation on an integrated monitoring system using an SAE J1939 or SmartCraft network protocol LINE CIRCUIT BREAKER gt CONTROL SWITCH amp STATUS INDICATOR LAMPS A n EMERGENCY ____ gt STOP SWITCH Pe HOUR METER D 22 OIL FILL NECK FIGURE 2 1 LOCAL CONTROL PANEL SmartCraft is a trademark of the Brunswick Corporation OPERATOR PANEL The remote Operator Panel has an LCD screen with 4 navigation butt
65. vice and product information Figure 1 1 illustrates the nameplate and its location 1 1 on the side of the control box Every character in these numbers is significant The last character of the model number is the specification letter which is important for obtaining the right parts Record the generator set model and serial numbers on the lines designated in the figure so that they are easy to find when you need them IMPORTANT ENGINE INFORMATION gt CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Spec Made in U S A KVA PH RPM Pf KW 50 Hz 60 Hz As Manufactured Freq Options AC Volts Amps Fuel Software Cfg Wire Diagram NEMA Class Ambient 40 C Insulation REFER TO OPERATOR S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS N 99 2495 MODEL NUMBER SERIAL NUMBER FIGURE 1 1 TYPICAL NAMEPLATE HOW TO OBTAIN SERVICE For generator set parts service and product infor mation such as the Service Manual contact the nearest authorized Cummins Onan distributor You may go to Internet site www cumminsonan com for information for contacting our distributors world wide In North America Call 1 800 888 ONAN for
66. y as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4 3 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime Replace the fuel filters and reprime p 4 6 Change the engine oil to oil of the proper viscosity for the ambient temperature High oil viscosity can slow down cranking speed WARNING SHUTDOWN DUE TO VESSEL CO CODE NO 5 Control Logic Dangerous levels of Carbon Monoxide in Vessel Corrective Action Get everyone out into fresh air immediately and seek medical attention LOSS OF RAW WATER FLOW CODE NO 7 Control Logic Insufficient raw water flow through the heat exchanger to cool the engine Corrective Action 1 Open the sea valve 2 Check for and clean a blocked sea water strainer If above the water line fill the strainer with water to assist priming 3 Check for and reconnect or replace any disconnected kinked or leaking raw water hoses 4 Check the bottom of the hull for any blockage at the through hull fitting 5 4 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe person al injury or death Only trained and experienced service personnel with knowledge of fuels electric ity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can ca

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