981-0176 ONAN MDKBH Marine Genset Operator`s manual (06
Contents
1. N 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 Break Thru Here Extinguisher Port 98 7472 FIGURE 3 2 FIRE EXTINGUISHER PORT Redistribution or publication of this document by any means is strictly prohibited 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 e Headache e Weakness and Sleepiness e Inability to Think Coherently e Dizziness e Nausea e Vomiting 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 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 accor dance with the genset Installation Manual PRE START CHECKS Before the first start of the day and after every eight hours of operation inspect the genset as instructed under GENERAL I2. live electrical equipment ref NFPA No 10 Genset installation and operation must comply with all applicable local state and federal codes and regulations GENERATOR VOLTAGE IS DEADLY Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes The genset must not be connected to shore power or to any other source of electrical pow er Back feed to shore power can cause elec tric shock resulting in severe personal injury or death and damage to equipment An approved switching device must be used to prevent inter connections Use caution when working 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 Redistribution or publication of this document by any means is strictly prohibited ENGINE EXHAUST IS DEADLY Never sleep in the boat while the genset is run ning unless the boat is equipped with properly working carbon monoxide detectors The exhaust system must be installed in accor dance with the genset Installation Manual and be free of leaks Make sure the bilge is adequately ventilated with a power exhauster Inspect for exhaust leaks every startup and af ter every eight hours of operation For more information about carbon monoxide see American Boat and Yacht Council ABYC publication TH 22 Educational
3. 4 3 FUEL FILTER 4 5 Redistribution or publication of this document by any means is strictly prohibited MAINTAINING THE ENGINE COOLING SYSTEM Refer to Table 4 1 for scheduled maintenance Cooling System Overview The engine is cooled by a pressurized closed loop liquid cooling system in which coolant is pumped through passages in the engine block head and 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 genset enclosure that the coolant recovery hose is con
4. 57 A local or remote control switch was held in the Prime position for more than 5 minutes Corrective Action Check for and remove any object that may be holding either control switch remote or local in the prime position HIGH EXHAUST TEMPERATURE CODE NO 58 Exhaust temperature exceeded design limits due to lack of water delivered to the exhaust water mixer Corrective Action 1 Check for and clean a blocked sea water strainer If above the water line fill the strainer with water to assist priming 2 Check for kinked or leaking hoses and reconnect reroute or replace 3 Inspect the siphon break if provided for proper operation 4 Check for a worn raw water impeller and replace as necessary p 4 10 5 Clean the heat exchanger p 4 12 EXTERNAL SHUTDOWN CODE NO 61 Genset was shut down by a fire suppression system or other external control Corrective Action Make all necessary repairs to the genset and connected equipment and reset the external control which shut down the genset 5 7 Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 6 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
5. Information About Carbon Monoxide DIESEL FUEL IS COMBUSTIBLE Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flames sparks pilot lights arc producing equipment and all other sources of ignition well away Fuel lines must be secured free of leaks and separated or shielded from electrical wiring GASOLINE IS FLAMMABLE AND EXPLOSIVE Because this genset is an gnition Protected device no substitutes are permitted for the parts listed in the Critical Parts Index of the genset Parts Catalog They must be pur chased from Onan and be installed in accor dance with the genset Service Manual by those who are trained and experienced in ma rine genset 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 Flammable vapor can cause a diesel engine to overspeed and become difficult to stop resulting in possible fire explosion
6. SWITCH BA Ni y E BLOCK DRAIN CAP EXHAUST amp RAW WATER OUT RAW WATER PUMP RAW WATER IN RAW WATER e FIGURE 4 4 ENGINE COOLING SYSTEM Redistribution or publication of this document 4 7 by any means is strictly prohibited Siphon Break Bypassing a siphon break or failing to maintain it can 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 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 Dis
7. 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 No Active Alarms ABACK FIGURE 2 6 ENGINE PRE ALARMS 2 5 Redistribution or publication of this document by any means is strictly prohibited Brightness and Contrast To adjust the brightness and contrast of the LCD screen and status lamps go to the SCREEN AD JUST screen by pressing SCREEN on any GEN STATUS screen Press NEXT to select Brightness or Contrast Increase or decrease the selected item by pressing the increase decrease buttons gt See Figure 2 7 Contrast applies only to the LCD screen Press 4BACK to save the settings and go back to GEN STATUS Display Setup Go to the SETUP screen by pressing SETUP on any GEN STATUS screen Press the up down arrows v a to select Display Setup and press ENTER See Figure 2 8 Units To change the units of measure on the GEN STATUS screens press NEXT to select Units Then press the up down arrows v to toggle between Metric and SAE units Press 4BACk to save the selection and go back to GEN STATUS AC Voltmeter Calibration To calibrate the Display Voltmeter press NEXT to select AC Voltmeter Calibration Then press the up down arrows v a to increase or decrease the voltage displayed to correspond to an accurate AC output voltmeter line to line or line to neutral as desired Press 4
8. hr Half Load 0 29 gph 1 1 liter hr 50 Hz 2400 3000 rpm Number of Cylinders Bore Stroke Displacement Compression Ratio Firing Order Clockwise Rotation Fuel Injection Timing 18 20 BTDC Fuel Injection Pressure Valve Lash cold Engine Oil Capacity Engine Oil Drain Connection Coolant Capacity 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 Waiter Inlet Connection 5 8 inch 15 9 mm ID Hose Maximum Fuel Pump Lit Recommended Fuel Line Size 3 8 inch 9 mm ID Fuel Supply Connection Fuel Retur Connection Maximum Exhaust Back Pressure 3 INCH 76 MM HG Wet Exhaust Outlet Connection Combustion Ar Generator Cooling Air Nominal Battery Voltage Minimum CCA Rating Battery Charging Output Size LxWxH Weight dry Noise 71 dB A 68 dB A Redistribution or publication of this document by any means is strictly prohibited Redistribution or publication of this document by any means is strictly prohibited 7 Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Sec 4 HOUR METER MAINTENANCE OR SERVICE PERFORMED Record the name address and phone number of your authorized Onan service center 7 1 Redistributio oublication of this um m by any means is st dE pro ohibite Redistribution or publication of this document by
9. running at the same time especially those with high motor starting loads such as air conditioners 3 Have air conditioners and other appliances checked for proper operation A locked compressor rotor can cause very low power factor CONTROL CARD FAILURE RAM CODE NO 43 During startup the genset Controller detected a RAM memory error Corrective Action See an authorized Onan service representative SPEED SENSE LOST CODE NO 45 After start disconnect the genset Controller lost speed sense quadrature zero crossings for 0 25 seconds Corrective Action See an authorized Onan service representative GENSET OVERLOAD CODE NO 46 The genset Controller shutdown the genset because engine load exceeded 135 percent of genset rating for 10 seconds Corrective Action Reduce the number of loads on the genset 5 6 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 TROUBLESHOOTING GENSET FAULTS CONT Some genset service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting OVERPRIME CODE NO
10. service as necessary p 4 9 NO AC POWER WHEN GENSET IS RUNNING A Circuit Breaker is OFF tripped or malfunctioning or the generator is not connected properly Corrective Action 1 Reset or turn ON the genset 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 HIGH ENGINE TEMPERATURE CODE NO 1 Engine coolant temperature exceed design limit Corrective Action 1 Check for and clean a blocked sea water strainer If above the water line fill the strainer with water to assist priming Check engine coolant level and add coolant as necessary Check for kinked or leaking hoses and reconnect reroute or replace Check the V belt that drives the coolant pump and service as necessary p 4 9 Inspect the siphon break if provided for proper operation Check for a worn raw water impeller and replace as necessary p 4 10 Clean the heat exchanger p 4 12 Check the bottom of the hull for any blockage at the through hull fitting 5 2 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 TROUBLESHOOTING GENSET FAULTS CONT Some genset service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions Accidental or
11. 50 200 600 Electric Broom 200 500 50 200 Electric Blanket Redistribution or publication of this document by any means is strictly prohibited NO LOAD OPERATION Keep no load operation to a minimum During no load operation cylinder temperatures drop to the point where fuel does not burn completely causing fuel wetting and white smoke It is best to run the genset at 1 4 to 3 4 load RESETTING LINE CIRCUIT BREAKERS If the genset line circuit breaker trips 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 genset will continue to run after a line circuit breaker trips If a circuit breaker trips disconnect or turn off as many loads as possible and reset the circuit break er If the circuit breaker trips right away either the electrical distribution system has a short or the cir cuit breaker is faulty Call a qualified electrician If the circuit breaker does not trip reconnect loads one by one up to a total load that does not overload the genset or cause the circuit breaker to trip The circuit probably has a short if the circuit breaker trips right away when it is connected Electrical equipment must be used and maintained 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 sever
12. BACK to save the selection and go back to GEN STATUS Note This procedure does not change AC output voltage Have a trained and experienced person ad just AC output voltage if necessary before calibrat ing the Display Voltmeter Genset and Display Information Go to the SETUP screen by pressing SETUP on any GEN STATUS screen Press the up down arrows v a to select Genset Info or Display Info and press ENTER See Figure 2 8 This information may be requested by the service technician Keep pressing 4BACK to get back to GEN STA TUS FROM SCREEN ar SCREEN ADJUST Contrast 4BACK NEXT FIGURE 2 7 SCREEN BRIGHTNESS amp CONTRAST FROM SETUP FIG 2 3 SETUP DISPLAY SETUP GENSET INFO DISPLAY INFO 4BACK E DISPLAY SETUP Units AC Volt Meter Calibration KMIiv 4BACK NEXT 4 GENSET INFO GENSET SW P N 3261234 V12 34 NIM SW P N 3261234 V12 34 UC MEN DISPLAY INFO SW P N 3261234 SW VERSION 12 34 SF P N 3261234 SF VERSION 10 23 FIGURE 2 8 SETUP GENSET amp DISPLAY INFO 2 6 Redistribution or publication of this document by any means is strictly prohibited 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 equipment Keep flames sparks pilot fla
13. NSPECTION p 4 2 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Returning the Genset to Service p 3 6 if the boat has been in storage Before each start 1 Make sure all CO detectors on board are work ing properly 2 Check for swimmers that might be exposed to the engine exhaust 3 Disconnect all electrical loads and disengage the PTO if so equipped PRIMING THE FUEL SYSTEM The fuel system should be primed after replacing the fuel filter or running the genset out of fuel To prime the fuel system Push and Hold STOP on the e Series Digital Display or STOP Prime on the control switch for at least 30 seconds 3 3 STARTING THE GENSET The genset can be started and stopped from the genset control panel or remote control panel 1 Push and Hold START on the e Series Digital Display or control switch until the genset starts The genset status lamp blinks when the engine is cranking and comes on and stays on when the genset starts and runs The status dis played on the e Series Digital Display changes from Starting to Running Figure 2 3 For longer engine life let the engine warm up for two minutes before connecting air condi tioners and other large electrical loads or en gaging the PTO if so equipped Check for water coolant fuel and exhaust leaks Stop the genset immediately if there is a leak Repair fuel leaks immediately Monitor generator set sta
14. ODE NO 27 The genset Controller lost VAC sensing during normal voltage regulation when the field was functioning normally and frequency was at least 40 Hz Corrective Action See an authorized Onan service representative HIGH BATTERY VOLTAGE CODE NO 29 During startup the genset Controller sensed that battery system voltage was greater than 19 2 volts Corrective Action 1 Check battery bank connections and reconnect if necessary for 12 volts 2 Select a lower battery booster charge rate STARTING FAULT CODE NO 32 The genset Controller could not detect cranking speed quadrature zero crossings for 3 seconds Corrective Action 1 Have the propulsion engines running while trying to start the genset Their charging alternators may be able to maintain a high enough battery terminal voltage to start the genset 2 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4 2 3 Change the engine oil to oil of the proper viscosity for the ambient temperature High oil viscosity can slow down cranking speed CONTROL CARD FAILURE EE CODE NO 35 During startup the genset Controller detected a EE memory error Corrective Action See an authorized Onan service representative 5 5 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 TROUBLESHOOTING GENSET FAULTS CONT Some genset servi
15. Printed in U S A Operator s Manual MDKBH 06 05 981 0176 Redistribution or publication of this document by any means is strictly prohibited California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Redistribution or publication of this document by any means is strictly prohibited Table of Contents SECTION PAGE SAFETY PRECAUTIONS 5 edi tired deat Aes hate heater Ae ND A e iii TAMNETRODUC TION frs eS or iode crt ost sald tod ede e e da e eO gh ER 1 1 About this Manual t ot boe ROC E P ec bbs y Bate Sate 1 1 Model ldentiticationic sais Siga zen eet E Edmond obese 1 1 How to Obtain Service 5 o ouod xc eed ex E eod ta Pte etd a eben Has is 1 2 Emissions Label 2 EIER ER I un pLebR EDS EIL LARA Ad 1 2 Z2AGONTBROL PANELS acted dures tutes ct i o e Eder e OTi ds eto E SOR 2 1 Local Gontrol Panel 5e ione dr te CE ap E Vcn CE SOM unn de 2 1 Remote Control and Monitoring lsseeleseeeesesnselseen 2 1 Digital Display ose exe eund we b etie d anon eed E EOD es rite unde Ny dn 2 2 3 OPERATION aces Lc E Co Ro Rt eat bo bees s Cate DO ee tnde D 3 1 Fuels REO or ROE E er Rn d MR DUE ME E 3 1 Engine Oil a vacinan rater ance dealing eat o D ees ial yaya e s ta o ete Roue IR o e EGRE Be 3 1 Engine Coolant e mods bite eecetr in Raub Eq door D ad bene cee ome 3 2 Batteries ql 3 2 Fire Exti
16. S LABEL The engine has a label on the air intake Figure 1 2 which states compliance with applicable EPA and California emissions regulations California users of this genset should be aware that unauthorized modifications or replacement of fuel exhaust air intake or speed control system compo nents that affect engine emissions are prohibited Unauthorized modification removal or replacement of the engine label is prohibited You should carefully review Operator Owner Installation and other manuals and information you received with your genset If you are unsure that the installation use maintenance or service of your genset is authorized you should seek assistance from an approved Onan dealer California genset users may use Table 1 1 as an aid in locating information about the California Air Re sources Board requirements for emissions control ENGINE EMISSIONS FIGURE 1 2 EMISSIONS LABEL TABLE 1 1 EMISSIONS CONTROL INFORMATION Emissions Warranty Information The California emissions control warranty statement is located in the same packet of in formation as this manual when the genset is shipped from the factory The engine is certified to operate on diesel fuel See FUEL RECOMMENDATIONS Engine Fuel Requirements Page 3 1 Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS Page 3 1 High Idle Speed This is a service procedure requiring trained personnel and proper Engine Adju
17. TO OPERATOR S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS 99 2495 MODEL NUMBER SERIAL NUMBER FIGURE 1 1 TYPICAL NAMEPLATE Redistribution or publication of this document by any means is strictly prohibited HOW TO OBTAIN SERVICE 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 For genset parts service and product information such as the Service Manual contact the nearest authorized Onan distributor You may go to Internet site www onan com for information for contacting our distributors worldwide In North America Call 1 800 888 ONAN for the nearest Cummins Onan distributor in the United States or Canada Press 1 OPTION 1 to be automatically connected If you are unable to contact a distributor using the automated service consult the Yellow Pages Typi cally our distributors are listed under GENERATORS ELECTRIC Outside North America Call Onan Corporation at 1 763 574 5000 from 7 30 AM to 4 00 PM Central Standard Time Monday through Friday or fax 1 763 528 7229 Information To Have Available 1 Model Number including Spec Letter and Seri al Number Figure 1 1 Date of purchase Nature of problem Section 5 Troubleshoot ing EMISSION
18. any means is strictly prohibited
19. aust leaks have been repaired Fuel System Check for leaks at hose tube and pipe fittings in the fuel supply and return systems while the genset is running and while it is stopped Check flexible fuel hose for cuts cracks abrasions and loose hose clamps Make sure fuel lines do not rub against oth 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 genset ran out of fuel Fuel leaks can lead to fire Repair leaks immediately Do not run the genset if it causes fuel to leak 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 6 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 genset opera tion Also when a water exhaust separator is pro 4 2 vided see Installation Manual open the sea cock for the water drain hose Check for and replace hoses that leak or are dam aged Battery Connections See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Mechan
20. ce procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting UNKNOWN SHUTDOWN CODE NO 36 The genset Controller declared this fault because engine speed fell below 1000 RPM for 0 5 seconds though not by genset or engine control action Corrective Action 1 Reduce the number of loads on the genset 2 Check fuel level and refill as necessary Note The genset fuel pickups are probably higher than the propulsion engine fuel pickups 3 Prime the engine fuel system for at least 30 seconds p 3 3 4 Check all fuel fittings for fuel and air leaks tighten as necessary and reprime 5 Replace the fuel filters and reprime p 4 5 INVALID GENSET CONFIGURATION CODE NO 37 The genset Controller is not configured properly for the genset Corrective Action See an authorized Onan service representative FIELD OVERLOAD CODE NO 38 High field voltage induced by high rotor temperature or low power factor loads Corrective Action 1 Remove blockages to generator air flow at the front inlet grill and right side if enclosed 2 Reduce the number of appliances
21. connect 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 2 Remove 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 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 4 8 THERMOSTAT FIGURE 4 5 TYPICAL THERMOSTAT Redistribution or publication of this document by any means is strictly prohibited Adjusting V Belt Tension See Table 4 1 for scheduled inspection or replace ment Adjust belt tension as follows 1 Disconnect the negative cable at the battery to prevent the engine from starting 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 Remove the front and top access doors If work space is limited remove the end panel Fig ure 4 6 to be able to hold the nut on the pump pivot bolt Figure 4 7 with an open end wrench while loosening the bolt Loosen both bolts so that the pump can pivot Pivot the pump out to tighten belt tension Hold tension by tightening the tension ad
22. e LOW AC VOLTAGE CODE NO 13 After voltage regulation was enabled Output Voltage fell to less than 90 of rated for 5 seconds Corrective Action Push the genset line circuit breaker OFF If the genset now runs reduce the num ber of loads HIGH AC FREQUENCY CODE NO 14 After the starter was engaged Frequency jumped to more than 70 Hz for 40 milliseconds or to more than 296 over nominal for 6 seconds Corrective Action 1 Check for a tripped genset circuit breaker reset it if necessary and run with fewer connected loads A breaker tripping under load can cause genset frequency to overshoot 2 Check all fuel fittings for fuel and air leaks and tighten as necessary and reprime Air bubbles can disrupt frequency LOW AC FREQUENCY CODE NO 15 During normal operation Frequency fell to less than 9096 of nominal for more than 8 seconds Corrective Action 1 Push the genset line circuit breaker OFF If the genset now runs reduce the number of loads espe cially those with high motor starting loads such as air conditioners 2 Check fuel level and fill as necessary 3 Prime the engine fuel system for at least 30 seconds p 3 3 4 Check all fuel fittings for fuel and air leaks tighten as necessary and reprime Air bubbles can dis rupt frequency Replace the fuel filters and reprime p 4 5 GOVERNOR OVERLOAD CODE NO 22 Maximum allowable time at full duty cycle was exceeded Corrective Action 1 Reduc
23. e personal injury or death Electrical equipment and its grounding must be main tained properly to protect against short circuits 3 5 CONNECTING TO SHORE POWER When provisions have been made for connecting shore power the boat must have an approved de vice to keep the genset and shore power from being interconnected Interconnecting the genset and shore power can lead to electrocution of utility line workers equipment damage and fire Use an approved switching device to prevent inter connections COLD TEMPERATURE OPERATION Do not let raw water freeze in the heat exchanger during cold weather when the genset is not operat ing Freezing water can damage the raw water tubes in the heat exchanger Engine coolant but not raw water is protected from freezing If freezing temperatures are expected see Heat Exchanger under Periodic Maintenance p 4 12 Also drain the muffler 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 4 EXERCISING THE GENSET Exercise the genset at least 1 hour every month if use is infrequent Run the genset at 1 4 to 3 4 load A single exercise period is better than several short er periods Exercising a genset drives off moisture re lubricates the engine uses up fuel before it be comes stale and removes oxides from electrical contacts The result is better starting more re
24. e 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 genset will run out of fuel before the propulsion engines Remove any blockage in the combustion air inlet front grille or exhaust system Check all fuel fittings for fuel and air leaks tighten as necessary and reprime Replace the fuel filters and reprime p 4 5 5 4 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 TROUBLESHOOTING GENSET FAULTS CONT Some genset service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting FAULTY OIL PRESSURE SENDER CODE NO 23 Controller sensed grounded sender Corrective Action See an authorized Onan service representative FAULTY TEMPERATURE SENDER CODE NO 24 Controller sensed open sender Corrective Action See an authorized Onan service representative LOSS OF AC VOLTAGE SENSE C
25. eaving the generator room Parts can bend or break leading to electrical shorts or to fuel coolant or exhaust leaks e To prevent accidental or remote starting while working on the genset disconnect the nega tive battery cable at the battery 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 Keep the genset drip pan and compartment clean Oily rags can catch fire Gear stowed in the compartment can restrict cooling Make sure all fasteners are secure and proper ly torqued Do not work on the genset when mentally or physically fatigued or after having consumed alcohol or drugs You must be trained and experienced to make adjustments while the genset is running hot moving or electrically live parts can cause se vere personal injury or death Used engine oil has been identified by some U S state and federal agencies as causing cancer or reproductive toxicity Do not ingest inhale or contact used oil or its vapors Ethylene glycol used as engine antifreeze is toxic to humans and animals Clean up spills and dispose of used engine coolant in accor dance with local environmental regulations Keep multi class ABC fire extinguishers handy Class A fires involve ordinary combus tible materials such as wood and cloth Class B fires combustible and flammable liquid fuels and gaseous fuels Class C fires
26. ece 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 Refilling Cooling System 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 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 Redistribution or publication of this document by any means is strictly prohibited EXHAUST COOLANT RESERVOIR HOSE BARB TO CONNECT o5 a O L Z lt x X Z lt gt tc LL gt O O Lu tc rr Z lt x EN Q Q O PRESSURE CAP amp COOLANT FILL NECK RAW WATER FLOW SENSOR HEAT EXCHANGER CLEANOUT COVER COULD BE CONNECTED TO THERMOSTAT HOUSING EXTERNAL SIPHON BREAK AT THIS POINT SEE INSTALLATION MANUAL s y Y COOLANT PUMP EXHAUST WATER MIXER WITH HIGH TEMPERATURE EXHAUST
27. ecure the oil fill plug which snaps into its Socket FIGURE 4 1 OIL FILL NECK AND DIPSTICK 4 3 Redistribution or publication of this document by any means is strictly prohibited CHANGING ENGINE OIL AND FILTER State and 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 genset before removing the oil fill plug 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 Refer to Table 4 1 for scheduled engine 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 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 d
28. eries Digital Dis play or blinking control switch status lamp to trouble shoot the genset Perform the step by step correc tive actions suggested If you are still unable to re solve the problem contact an authorized Onan ser vice representative See How to Obtain Service p 1 2 Many genset shutdowns can be avoided by perform ing periodic maintenance on schedule TABLE 4 1 PERIODIC MAINTENANCE SCHEDULE and by not running the genset out of fuel Note that when gen sets and propulsion engines draw from the same fuel tanks the fuel dip tubes are usually arranged so that the gensets run out of fuel first By marking the gen set empty points on the fuel gauges it will be easier to tell when to stop the gensets before running them out of fuel TROUBLESHOOTING WITH DIGITAL DISPLAY If a fault shutdown occurs the ALARM status lamp on the e Series Digital Display will blink and the LCD screen will display the Fault Number a description of the Fault and the hour in total genset running time when the Fault occurred Figure 2 4 The fault will be displayed indefinitely Touch any button to clear the fault The display will turn off in 5 minutes after the fault has been cleared Last Five Faults See Page 2 5 to display any of the last five faults in fault history 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 O
29. he 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 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 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 Ib 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 4 12 FLOW SENSOR MOUNTING BOLT CLEANOUT COVER DRAIN PLUG FIGURE 4 10 HEAT EXCHANGER Redistribution or publication of this document by any means is strictly prohibited 5 Troubleshooting Use TABLE 5 1 TROUBLESHOOTING GENSET FAULTS in conjunction with the e S
30. ical Monitor generator set status using the e Series Dig ital Display p 2 3 Look for mechanical damage and listen for unusual noises when the genset is running Check the gen set mounting bolts Check to see that the genset air inlet and outlet openings are not clogged with debris or blocked Keep the genset compartment clean MAINTAINING THE BATTERY AND BATTERY CONNECTIONS 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 genset and dis connect 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 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 nega
31. justing 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 Tighten the bolts reassemble the panels and doors and reconnect the battery cables nega tive last 4 9 REMOVE THESE SEE DOORS amp PANELS TENSION ADJUSTING REMOVE THESE 7 SCREWS 3 8 INCH DRIVE SOCKET USE TO TENSION BELT PUMP PIVOT BOLT SPACER WASHER LOCKWASHER amp NUT FIGURE 4 7 ADJUSTING V BELT TENSION Redistribution or publication of this document by any means is strictly prohibited Replacing the Raw Water Pump Impeller See Table 4 1 for scheduled replacement Have towels and containers ready and avoid spilling raw water on the electrical components below the pump Referring to Figures 4 8 and 4 9 replace the impel ler as follows 1 2 Close the sea cock Disconnect the negative cable at the battery to prevent the engine from starting 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 Remove the front and top access doors If work space is limited remove the end panel Fig ure 4 6 to be able to hold the nut on the pump pivot bolt Figure 4 8 with an open end wrench while loosening the bolt Loosen the hose clamps shown in Figure 4 8 and disc
32. liable operation and longer engine life Redistribution or publication of this document by any means is strictly prohibited STORING THE GENSET Proper storage is essential for preserving top gen set performance and reliability when the genset cannot be exercised regularly and will be idle for more than 120 days Storing the Genset 1 2 Turn off the genset line circuit breaker p 2 1 Change the engine oil and filter and attach a tag indicating oil viscosity See ENGINE OIL REC OMMENDATIONS p 3 1 Crank the engine several revolutions but do not let it start This will fill the oil passages with the new oil 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 2 Check coolant level and add as necessary p 4 6 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 If freezing temperatures are expected see Heat Exchanger under Periodic Maintenance p 4 12 Also drain the muffler 7 Clean and lightly oil parts that can rust Returning the Genset to Service 1 Check the oil tag on the genset and change the oil if the visco
33. lt has been cleared Press 4BACK to go back to the GEN STATUS screen 2 4 FAULT Speed Sense Lost Fault No Hour ld BACK ALARM HIST 45 FIGURE 2 4 TYPICAL FAULT SCREEN Redistribution or publication of this document by any means is strictly prohibited Fault History To display any of the last five faults press the FAULT button on any GEN STATUS screen Then press the HIST button on the FAULT screen Figure 2 5 The FAULT HISTORY screen will display the last Fault Number a description of the Fault and the hour in total genset running time when the fault oc curred Press the double arrows Y to toggle be tween 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 Alarms 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 genset as required FROM FAULT FIG 2 3 FAULT No Active Faults HIST FAULT HISTORY Speed Sense Lost Fault No 45 Hour 10000 1 1of5 rec EN T OR FAULT HISTORY No Stored Faults FIGURE 2 5 FAULT HISTORY E FAULT Eng
34. mes electrical arcs and switches and all other i AE f 32 sources of ignition well away Keep a multi OF 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 ee ae OC 4 29 28 8 2 7 1 4 10 16 20 27 32 38 43 48 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 PAURE PIA ERAON S TANBEN mended Use Grade 1 D diesel fuel if the fuel tank is exposed to temperatures below 40 F 5 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 Cl 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 Redistribution or publication of this document by any means is strictly
35. nd corroding or clogging fuel in jection components The genset has a water separator fuel filter Fig ure 4 3 Check for other up stream filters which may also need 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 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 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 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 Clean the contact surface on the filter base lu bricate the new filter gasket and spin the new filler on hand tight Prime the engine for at least 30 seconds Page 3 3 to fill the new filter Run the genset and check for leaks Tighten the filter by hand if necessary FILTER FIGURE
36. ne 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 blink Pressing Stop again will stop the blinking The two digit code consists of 1 to 7 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the second set of blinks the units digit of the shutdown code number For example 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 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 TROUBLESHOOTING GENSET FAULTS 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 elec
37. nected 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 components Pressure Cap Replace the pressure cap every two years seals deteriorate and leak Proper cooling system pres sure 10 psi is essential for optimal engine cooling and minimal coolant loss Coolant Hoses Check for and replace hoses that leak or are dam aged 4 6 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 Hot coolant spray can cause severe burns Let the engine cool before releasing the pressure cap or removing the drain cap 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 Figure 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 pi
38. nguisher Port Ese PRU S eigaadal AX EDER E DA ERA IA 3 2 Pre Start GUSOKS asco tud sucer i dde o Padus RR AG EFT SU D E 3 3 Priming the Fuel System ono anam en e D rp ROC S ue oe ds 3 3 Starting the Genset 2 048 dee UR AEn Rd RO SR ER rt AT AUR eden eee it 3 3 Stopping this Gensel cu oes ipei exte red a net ds PEOR HEU DN S ere d cv t 3 4 Emergency Stop eric rA OEC X eb hee Ex DDR E badges eb 3 4 Loading the Genset tox tc eee oa aside Se ede Cees du d 3 4 No sLoad ODSIAllON sue rs tais us aed oe ieee eo Meo et wae tate esata HC ss 3 5 Resetting Line Circuit Breakers 0 0 0 cece eects 3 5 Connecting to Shore Power 00 0 eee ee eect eee ees 3 5 Cold Temperature Operation 00 cece eee eee tees 3 5 Care of New or Re Built Engine 0 0 c eee ees 3 5 Exercising the Genset usos uh ct ete eh cade Mie LAM cR Eo e E 3 5 Storing ihe Genset seo eder LNPEVI FE sek dueue eee eee CEP LR RRLESUEEFRI 3 6 i Redistribution or publication of this document by any means is strictly prohibited SECTION PAGE 4 PERIODIC MAINTENANCE 5 5 4 3 5 30 EC o CC HR IC ede e OR 4 1 General Inspection 2 2 ian ead eee ene tex rR ENERO ER OEEAT EK RR 4 2 Maintaining the Battery and Battery Connections 0 00000 4 2 Checking Engine Oil Level 223 ves cpr EE ED EX RI AY EU Rs 4 3 Changing Engine Oil and Filter cus Dre ERES eee EMUF EP PE ee xe 4 4 Draining Replacing the Fuel Filter suulelsee
39. nt by any means is strictly prohibited Genset Status Genset status is displayed on 3 screen pages Fig ure 2 3 GEN STATUS PG1 appears when the Dis GEN STATUS Pol play is turned on Press the double arrows V to Status Starting toggle between the 3 screen pages AC Volts 120V AC Freq 60Hz The Status line on PG1 will display the word Prim ing Starting Running Stopped or Volt Adj The ETUPIFAULT SCREE rest of the lines on the 3 status screen pages display AC output voltage AC frequency engine coolant temperature engine oil pressure starting battery voltage and total genset running time GEN STATUS Cool Temp 123F C EE Oil Press ETUP IFAULT SCREE GEN STATUS Pg3 Batt Volt 12 5V Hr Meter 12345 6 ETUP FAULT JSCREE FIGURE 2 3 TYPICAL GENSET STATUS SCREENS 2 3 Redistribution or publication of this document by any means is strictly prohibited Fault Screen If a fault shutdown occurs the ALARM status lamp will blink and the LCD screen will display the Fault Number a description of the Fault and the hour in total genset running time when the Fault occurred Figure 2 4 Refer to TABLE 5 1 TROUBLE SHOOTING GENSET FAULTS to diagnose and correct the problem The e Series Digital Display will display the fault in definitely Touch any button to clear the fault The display will turn off in 5 minutes after the fau
40. ntities Genuine Onan replace ment parts are recommended for best results MODEL IDENTIFICATION Be ready to provide the genset model and serial numbers on the nameplate when contacting Onan for parts service and product information Fig ure 1 1 illustrates the nameplate and its location on the side of the control box Every character in these numbers is significant The last character of the model number is the specification letter which is im portant for obtaining the right parts Record the gen set model and serial numbers on the lines desig nated in the figure so that they are easy to find when you need them Because this genset is an Ignition Protected Device no substitutes are permitted for the parts listed in the Critical Parts Index of the genset Parts Catalog They must be pur chased from Onan and be installed in accor dance with the genset Service Manual by those who are trained and experienced in marine gen set service 1 1 IMPORTANT ENGINE INFORMATION CUMMINS POWER GENERATION 1400 73rd Ave NE Minneapolis MN 55432 Spec Made in USA KVA Pf KW PH RPM 50 Hz 60 Hz As Manufactured Freq AC Volts Amps Options Insulation NEMA Class Fuel Software Cfg Wire Diagram Ambient 40 C M R EFER
41. oes 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 parts sooner at startup Spin the new filter on by hand until the gasket just touches the mounting pad and tighten 3 4 turn 6 Refill the engine with the proper type and amount of engine oil See ENGINE OIL REC OMMENDATIONS p 3 1 and Specifications p 6 1 Check the oil level and add or drain oil as necessary Too little oil can cause severe engine damage Too much oil can cause high oil consumption 7 Close the access door and dispose of the used oil and oil filter according to local environmental regulations 4 4 OIL DRAIN OIL VALVE FILTER FIGURE 4 2 OIL FILTER AND DRAIN VALVE Redistribution or publication of this document by any means is strictly prohibited DRAINING REPLACING THE FUEL FILTER 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 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 Keep dirt water and other contaminants from enter ing the fuel system a
42. onnect the hoses Loosen the two pump mounting bolts and re 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 4 10 TENSION LOOSEN THESE ADJUSTING 2 HOSE CLAMPS PUMP PIVOT BOLT SPACER WASHER LOCKWASHER amp NUT FIGURE 4 8 REMOVING RAW WATER PUMP Redistribution or publication of this document by any means is strictly prohibited 11 12 Remove the 4 pump cover screws Figure 4 9 and remove the impeller and O ring Use two pliers to grip vanes on opposite sides if the im peller is difficult to remove t will be necessary to check for and cleanout pieces of the impeller from the heat exchanger and exhaust elbow if vanes have broken off Install the new impeller It helps to twist the im peller clockwise the way it turns while squeez ing it into the housing To provide initial lubrication and better pump suction before water reaches the pump wet the inside of the pump and impeller with water soap solution or a silicone lubricant Do not lubricate the impeller with grease or oil or other petroleum prod ucts because they known to chemically at tack impeller materials Secure the cover and O ring Remount the pump reconnect the hoses ad just V belt tension Page 4 9 and reassemble the enclosure panels and doors Fill
43. prohibited ENGINE COOLANT 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 Section 6 Specifications regarding coolant ca pacity Ethylene Glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances BATTERIES Reliable genset starting and starter service life de pend upon adequate battery system capacity and maintenance See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 4 2 and Sec tion 6 Specifications FIRE EXTINGUISHER PORT A genset with an enclosure has a fire extinguisher port accessible by breaking through the circle on the warning label located as shown in Figure 3 2 Make sure that the nozzle of the fire extinguisher that will be used in the event of fire is smaller than the circle so that it will fit through the port The fire extinguisher must be of the gaseous type In the event of fire 1 DO NOT open the genset enclosure 2 Shut down engines generators and blowers 3 Break through the circle on the label with the nozzle and discharge the full contents of the fire extinguisher 3 2
44. rcuit breaker protects the AC power leads connected to the genset from overloads and equip ment short circuits Hour Meter The hour meter records genset operating time in hours It cannot be reset REMOTE CONTROL AND MONITORING Remote Control The boat may be equipped with several remote con trol stations having e Series Digital Displays p 2 2 or control switches with status lamps Boat Monitoring System The boat may be equipped to monitor genset opera tion on an integrated monitoring system using an SAE J1939 or SmartCraft network protocol LINE CIRCUIT BREAKER CONTROL SWITCH amp STATUS INDICATOR LAMPS EMERGENCY STOP SWITCH Nn HOUR METER OIL FILL NECK FIGURE 2 1 LOCAL CONTROL PANEL SmartCraft is a trademark of the Brunswick Corporation Redistribution or publication of this document by any means is strictly prohibited DIGITAL DISPLAY The e Series Digital Display has an LCD screen with 4 navigation buttons 3 status lamps a START O Oo mcr button and a STOP button Figure 2 2 Sates PRE ALARM Turning On the Display S ALARM Touch any button to turn on the Display which will initialize and attempt to establish communications with the genset controller All connected Displays SART ISTOR will tu
45. 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 OIL PRESSURE CODE NO 2 Low oil pressure Corrective Action Check engine oil level add or drain oil as necessary and repair any leaks p 4 3 SERVICE CHECK CODE NO 3 A fault with a 2 Digit Fault Code Number occurred Corrective Action Check the 2 Digit fault code by Pushing and Releasing Stop The 2 Digit fault will be one of the following in this table Does not apply to e Series Digital Display OVERCRANK CODE NO 4 Cranking time exceeded 20 to 60 seconds depending on ambient temperature Corrective Action 1 Check fuel level and refill as necessary Note The genset fuel pickups are probably higher than the propulsion engine fuel pickups Open any closed fuel supply and return valves Prime the engine fuel system for at least 30 seconds p 3 3 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4 2 Replace the fuel filters and reprime p 4 5 Check all fuel fittings for fuel and air leaks tighten as necessary and reprime 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 Dange
46. rn on automatically when the genset is started AS at any station They will all turn off 5 minutes after Il I Il O the genset has received a normal command to stop They will stay on indefinitely until a fault shutdown is w AL cleared by touching any button on any Display s Mai e Start Button Starting the Genset Push and Hold START until FIGURE 2 2 DIGITAL DISPLAY the genset starts The GENSET status lamp blinks while the engine is cranking It comes on when the genset starts and stays on while it runs The status displayed on the LCD changes from Starting to Run ning Figure 2 3 See STARTING THE GENSET p 3 3 Stop Button Stopping the Genset Push and Release STOP The GENSET status lamp will go out The status displayed on the LCD will change from Running to Stopped Figure 2 3 See STOPPING THE GEN SET p 3 4 Priming the Fuel System Push and Hold STOP The GENSET status lamp will blink The status dis played on the LCD will change to Priming in 2 sec onds Figure 2 3 See PRIMING THE FUEL SYS TEM p 3 3 Genset Status Lamps GENSET This status lamp green blinks while the engine is cranking or the fuel system is being primed It stays on while the genset is running PRE ALARM This status lamp amber comes on when an engine Pre Alarm condition exists p 2 5 ALARM This status lamp red blinks during fault shutdown p 2 4 2 2 Redistribution or publication of this docume
47. rous levels of Carbon Monoxide in Vessel Corrective Action Get everyone out into fresh air immediately and seek medical attention LOSS OF RAW WATER FLOW CODE NO 7 Low raw water pressure in heat exchanger Corrective Action 1 Open the sea cock 2 Check for and clean a blocked sea water strainer If above the water line fill the strainer with water to assist priming 3 Check for kinked or leaking hoses and reconnect reroute or replace 4 Check for a worn raw water impeller and replace as necessary p 4 10 5 Check the bottom of the hull for any blockage at the through hull fitting 5 3 Redistribution or publication of this document by any means is strictly prohibited TABLE 5 1 TROUBLESHOOTING GENSET FAULTS CONT Some genset service procedures present hazards that can result in severe personal injury or death Only trained and experienced service personnel with knowledge of fuels electricity and machinery hazards should perform genset service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting HIGH AC VOLTAGE CODE NO 12 After voltage regulation was enabled Output Voltage jumped to more than 125 of rated for 75 millisec onds or to more than 115 of rated for 3 seconds Corrective Action See an authorized Onan service representativ
48. s 500 Hrs Every Every 800 Hrs 2 Years ears mere SE PP mexmemonas dt P e oanviertonruerm _ rex tay mesaer Goes p f crea vetao Ss E a e Prapexspronsk SY E a e cnc Ene oiaorreer f f Pewenames dt P Po Freon Raw wawrmeae xe Pawee S a Replace Coolant Pressure Cap amp Thermostat EE E pu ES Et Te one Check Generator Bearings Drive Belt Belt Tensioner amp Drive Coupling 1 Includes inspection of Oil Level Coolant Level Fuel System Exhaust System Batteries and Battery Connections 2 See battery manufacturer s recommendations 3 Check for slippage cracking and wear pump drive belt only 4 There is no zinc anode to replace 5 Must be performed by a qualified mechanic authorized Onan dealer in accordance with the engine and genset Service Manuals Redistribution or publication of this document by any means is strictly prohibited GENERAL INSPECTION Inspect the genset before the first start of the day and after every eight hours of operation Oil Level Check engine oil level p 4 3 Exhaust System 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 EXHAUST GAS IS DEADLY Do not operate the genset until all exh
49. seeeseeseessse 4 5 Maintaining the Engine Cooling System 0 00 0 cee eee 4 6 5 TROUBLE SHOOTING x tuo add eb bats ma metui Os de ta e d oa Obf o a ms 5 1 Troubleshooting with Digital Display 00 cece ee 5 1 Troubleshooting with Status Lamp 0 cece eee eee eee 5 1 6 SPECIFICATIONS a 4 viet iced CR n DRE SI Ea a a eR RAG CRURA CO Cost ad t ate 6 1 7 MAINTENANCE RECORD 2 844880 tto wit e o Rd o Vg t eacus 7 1 i Redistribution or publication of this document by any means is strictly prohibited SAFETY PRECAUTIONS Thoroughly read the OPERATOR S MANUAL before operating the genset Safe operation and top performance can only be obtained when equipment is operated and maintained proper ly 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 genset e Do not use evaporative starting fluids They are highly explosive e Do not step on the genset when entering or l
50. severe personal injury and death Do not operate a diesel powered genset where a flammable vapor environment can be created by fuel spill leak etc The owners and operators of the genset are solely responsible for operating the genset safely POST THESE SAFETY PRECAUTIONS IN POTENTIAL HAZARD AREAS OF THE BOAT Redistribution or publication of this document by any means is strictly prohibited 1 Introduction ABOUT THIS MANUAL This is the Operator s Manual for the generator sets gensets listed on the front cover Each operator should study this manual carefully and observe all of its instructions and safety precautions Keep this manual handy for ready reference This genset is not a life support sys tem It can stop without warning Children per sons with physical or mental limitations and pets could suffer personal injury or death A per sonal attendant redundant power or alarm sys tem must be used if genset operation is critical Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for op erating the genset and maintaining it at top perfor mance The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE p 4 1 This manual also includes genset specifications information on how to obtain service and information regarding compliance with emissions regulations See the Parts Manual for part identification numbers and required qua
51. sity 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 2 Replace the raw water pump impeller if it was installed more than a year ago p 4 10 Perform the maintenance required p 4 1 conduct the pre start checks and prime the fuel system Start and run the genset Turn on the genset line circuit breaker p 2 1 when ready to power loads Redistribution or publication of this document by any means is strictly prohibited 4 Periodic Maintenance Periodic maintenance is essential for top perfor mance and long genset life Use Table 4 1 as a guide for normal periodic maintenance Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever warranty work must be completed by an au thorized Onan service representative To help you keep genset maintenance regular and provide a basis for warranty claims record mainte nance performed in Maintenance Record p 7 1 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 genset TABLE 4 1 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE FREQUENCY MAINTENANCE OPERATION 100 Hrs 200 Hr
52. stments tools See the Service Manual ture The engine emission control system consists of engine design and precision manufac Engine Emission Control System IFI 1 2 Redistribution or publication of this document by any means is strictly prohibited 2 Control Panels LOCAL CONTROL PANEL Refer to Figure 2 1 Control Switch Starting Push and Hold START to preheat crank and start the genset The green lamp comes on when the genset is running Preheat is the period of time prior to engine cranking when the glow plugs preheat the combustion chambers The time is au tomatically varied by the genset controller on the ba sis of engine temperature Stopping Push and Release STOP Prime to stop the genset 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 genset shuts down abnormally this lamp will slowly blink a numerical code to indicate the cause of shutdown See Section 5 Trouble shooting The green status lamp comes on to indi cate that the genset is running Emergency Stop Switch In an emergency push the switch to OFF Push it to ON after all necessary repairs to the genset and connected equipment have been made Line Circuit Breaker The line ci
53. the sea water strainer for faster priming at startup if it is above the water line Open the sea cock reconnect the battery cables negative last and start the genset The genset will shut down within 8 seconds if there is no raw water flow and Fault Code No 7 p 5 3 will be declared If it shuts down find out why remove any blockage and restart the genset 4 11 IMPELLER COVER AND SCREWS FIGURE 4 9 REPLACING THE IMPELLER Redistribution or publication of this document by any means is strictly prohibited Heat Exchanger The heat exchanger has a cleanout cover and drain plug Figure 4 10 Clean the raw water tubes if the engine keeps shutting down Code No 1 or the en gine gauge indicates abnormally high engine tem peratures Drain the heat exchanger of 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 end enclosure panel or the raw water pump see Replacing the Raw Water Pump Impeller Page 4 10 Have towels and containers ready to prevent spilling raw water on the electrical compo nents below the heat exchanger Remove the drain plug or cleanout cover Clean and flush the tubes The drain plug must be removed to get all the water out of t
54. tive cable first and reconnecting it last to reduce arcing Redistribution or publication of this document by any means is strictly prohibited CHECKING ENGINE OIL LEVEL OIL FILL NECK WITH PLUG AND ATTACHED State and federal agencies have de DIPSTICK 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 genset before removing 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 KEEP OIL LEVEL aee BETWEEN THESE TWO end of the dipstick as shown It is not neces BEADS ON DIPSTICK sary to add oil between oil changes if the oil has nnd 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 S
55. tricity and machinery hazards should perform genset service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting NO RESPONSE AT DIGITAL DISPLAY OR CONTROL SWITCH Faulty switch poor or missing connections dead battery Corrective Action 1 At the genset control panel push the emergency stop switch On 2 Try the Digital Display or control switch on the genset local if there is no response at the remote Display or control switch and vice versa 3 Check for battery voltage at the battery cable terminals on the genset Service as necessary by cleaning and tightening battery cable connections recharging or replacing the battery or replacing damaged or missing battery cables p 4 2 THE STARTER ENGAGES AND DISENGAGES Low cranking voltage Corrective Action Service as necessary by cleaning and tightening battery cable connections re charging or replacing the battery or replacing damaged battery cables p 4 2 THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE Marginal battery battery connections or charging system Corrective Action 1 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4 2 2 Inspect the serpentine belt that drives the charging alternator and
56. tus 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 genset fails to start cranking will dis continue in 20 to 60 seconds depending on en gine temperature The e Series Digital Display and or control switch status lamp will indicate Fault Code No 4 See Troubleshooting Sec 5 if the genset does not start after sever al 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 genset does not start and make necessary repairs If the genset shuts down the e Series Digital Display and or control switch status lamp will indicate the numeric fault code See Trouble shooting Sec 5 Redistribution or publication of this document by any means is strictly prohibited STOPPING THE GENSET Disconnect all electrical loads and disengage the PTO if so equipped to let the genset run without load and cool down After 2 minutes Push and Re lease STOP on the e Series Digital Display or con trol switch The genset status lamps will go out EMERGENCY STOP Push the EMERGENCY STOP SWITCH to OFF p 2 1 After all necessary repairs have been made push the switch to ON so that the genset can be operated LOADING THE GENSET How much equipment load can be powered de pends
57. upon the genset power rating The genset will shut down or its AC output circuit breakers will trip if the sum of the loads exceeds genset power or cir cuit breaker rating To avoid overloading the genset and causing shut downs 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 genset Use Table 3 2 or the ratings on the appliances themselves to obtain the individual appliance loads If the appliance is marked in amps and volts only multiply the amps times the volts to obtain the appliance load watts It may be necessary to run fewer appliances at the same time the sum of the loads must not be greater than genset rating The genset may shut down due to overload when a large motor or air conditioner is started or cycles off and then on again even though the sum of the loads is less than genset rating The reason for this is that a motor s startup load is much larger than its running load It may be necessary to run fewer loads when large motors and air conditioners are cycl ing on and off The genset is rated at standard barometric pres sure humidity and temperature ref ISO 3046 Ei ther low barometric pressure high altitude or high ambient temperature will decrease engine power t may be necessary to run fewer loads under such conditions 3 4 TABLE 3 1 TABLE 3 2 TYPICAL APPLIANCE LOADS Electric Stove Element 50 200 Electric Drill 250 7
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