Cummins Onan Marine Generator Set Service & Repair Manual

MDKBK MDKBL MDKBM MDKBN MDKBP MDKBR MDKBS MDKBT MDKBU 981-0175C 01-07 Operator’s Manual Downloaded from www.Manualslib.com manuals search engine

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. Downloaded from www.Manualslib.com manuals search engine

i Table of Contents SECTION PAGE SAFETY PRECAUTIONS iii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. INTRODUCTION 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . About this Manual 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Identification 1-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Obtain Service 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emissions Label 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2. CONTROL PANEL 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Control and Monitoring 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Control Panel 2-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital Display 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3. OPERATION 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Oil 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Coolant 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Batteries 3-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fire Extinguisher Port 3-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Start Checks 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Priming the Fuel System 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting the Genset 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Genset 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop 3-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading the Genset 3-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . No-Load Operation 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resetting Line Circuit Breakers 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Connecting to Shore Power 3-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cold Temperature Operation 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Care of New or Re-Built Engine 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exercising the Genset 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Storing the Genset 3-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downloaded from www.Manualslib.com manuals search engine

ii SECTION PAGE 4. PERIODIC MAINTENANCE 4-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Inspection 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining the Battery and Battery Connections 4-2 . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Engine Oil Level 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing Engine Oil and Filter 4-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining/Replacing Fuel Filters 4-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintaining the Engine Cooling System 4-7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5. TROUBLESHOOTING 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting with Digital Display 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Troubleshooting with Status Lamp 5-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6. SPECIFICATIONS 6-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7. MAINTENANCE RECORD 7-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Downloaded from www.Manualslib.com manuals search engine

iii SAFETY PRECAUTIONS Thoroughly read the OPERATOR’S MANUAL before operating the genset. Safe operation and top performance can only be obtained when equipment is operated and maintained properly. The following symbols in this manual alert you to potential hazards to the operator, service person and equipment. DANGER alerts you to an immediate hazard that will result in severe personal injury or death. WARNING alerts you to a hazard or unsafe practice that can result in severe personal injury or death. CAUTION alerts you to a hazard or unsafe practice that can result in personal injury or equipment damage. Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death. ENGINE EXHAUST IS DEADLY • Never sleep in the boat while the genset is running unless the boat is equipped with properly working carbon monoxide detectors. • The exhaust system must be installed in accordance with the genset Installation Manual and be free of leaks. • Make sure the bilge is adequately ventilated with a power exhauster. • Inspect for exhaust leaks every startup and after every eight hours of operation. • For more information about carbon monoxide see American Boat and Yacht Council (ABYC) publication TH-22—Educational Information About Carbon Monoxide. GENERATOR VOLTAGE IS DEADLY • Generator electrical output connections must be made by a trained and experienced electri- cian in accordance with applicable codes. • The genset must not be connected to shore power or to any other source of electrical power. Back-feed to shore power can cause electric shock resulting in severe personal injury or death and damage to equipment. An approved switching device must be used to prevent inter- connections. • Use caution when working on live electrical equipment. Remove jewelry, make sure clothing and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles. DIESEL FUEL IS COMBUSTIBLE • Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equipment. Keep flames, sparks, pilot lights, 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. MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH • Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts and pulleys. • Keep hands away from moving parts. • Keep guards in place over fans, belts, pulleys, and other moving parts. BATTERY GAS IS EXPLOSIVE • Wear safety glasses. • Do not smoke. • To reduce arcing when disconnecting or recon- necting battery cables, always disconnect the negative (−) battery cable first and reconnect it last. Downloaded from www.Manualslib.com manuals search engine

iv 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, severe personal injury and death. Do not operate a diesel-powered genset where a flammable vapor environment can be created by fuel spill, leak, etc. The owners and operators of the genset are solely responsible for operating the genset safely. GENERAL PRECAUTIONS • Keep children away from the genset. • Do not use evaporative starting fluids. They are highly explosive. • Do not step on the genset when entering or leaving the generator room. Parts can bend or break leading to electrical shorts or to fuel, coolant or exhaust leaks. • To prevent accidental or remote starting while working on the genset, disconnect the negative (−) battery cable at the battery. • Let the engine cool down before removing the coolant pressure cap or opening the coolant drain. Hot coolant under pressure can spray and cause severe burns. • 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 properly torqued. • Do not work on the genset when mentally or physically fatigued or after having consumed alcohol or drugs. • You must be trained and experienced to make adjustments while the genset is running—hot, moving or electrically live parts can cause severe personal injury or death. • Used engine oil has been identified by some U. S. state and federal agencies as causing cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors. • Ethylene glycol, used as engine coolant, is tox- ic to humans and animals. Clean up spills and dispose of used engine coolant in accordance with local environmental regulations. • Keep multi-class ABC fire extinguishers handy. Class A fires involve ordinary combustible materials such as wood and cloth; Class B fires, combustible and flammable liquid fuels and gaseous fuels; Class C fires, live electrical equipment. (ref. NFPA No. 10) • Genset installation and operation must comply with all applicable local, state and federal codes and regulations. POST THESE SAFETY PRECAUTIONS IN POTENTIAL HAZARD AREAS OF THE BOAT M-10 Downloaded from www.Manualslib.com manuals search engine

1-1 1. Introduction ABOUT THIS MANUAL This is the Operator’s Manual for the generator sets (gensets) listed on the front cover. Each operator should study this manual carefully and observe all of its instructions and safety precautions. Keep this manual close at hand for reference. WARNING This genset is not a life support system. It can stop without warning. Children, per- sons with physical or mental limitations, and pets could suffer personal injury or death. A personal attendant, redundant power or alarm system must be used if genset operation is critical. Operation, Periodic Maintenance and Trouble- shooting provide the instructions necessary for operating the genset and maintaining it at top performance. The owner is responsible for performing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE (p. 4-1). This manual also includes genset specifications, information on how to obtain service, and information regarding compliance with emissions regulations. See the Parts Manual for part identification numbers and required quantities. Genuine Onan® replacement parts are recommended for best results. 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 genset model and serial numbers on the lines desig- nated in the figure so that they are easy to find when you need them. WARNING Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property. Ser- vice personnel must be qualified to perform electrical and mechanical service. MODEL NUMBER: ______________________ SERIAL NUMBER: ______________________ FIGURE 1-1. TYPICAL NAMEPLATE Downloaded from www.Manualslib.com manuals search engine

1-2 HOW TO OBTAIN SERVICE For genset parts, service, and product information (such as the Service Manual), contact the nearest authorized Cummins/Onan distributor. You may go to Internet site www.onan.com for information for contacting our distributors worldwide. In North America Call 1-800-888-ONAN for the nearest Cummins/ Onan distributor in the United States or Canada. Press 1 (OPTION 1) to be automatically connected. If you are unable to contact a distributor using the automated service, consult the Yellow Pages. 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). EMISSIONS LABEL The label that states compliance with applicable engine emissions regulations is located on the engine as circled in Figure 1-2. Refer also to the FEDERAL EMISSION DESIGN AND DEFECT LIMITED WAR- RANTY FOR C. I. ENGINES (DIESELS) that was shipped in the same package as the Operator’s Manual. FIGURE 1-2. TYPICAL EMISSIONS LABEL LOCATIONS Downloaded from www.Manualslib.com manuals search engine

2-1 2. Control Panel REMOTE CONTROL AND MONITORING Remote e-Series Digital Displays and Control Switches The boat may be equipped with several remote genset control stations having either an e-Series Digital Display or control switch. Boat Monitoring System The boat may also be equipped to monitor genset operation on an integrated monitoring system using an SAE J1939 or SmartCraft™ network protocol. LOCAL CONTROL PANEL Refer to Figure 2-1. Control Switch Panel (Standard) Control Switch: This switch is used to start and stop the genset and prime fuel. • Push and Hold START to preheat, crank and start the genset. The green lamp comes on when the genset is running. (Preheat is the pe- riod of time prior to engine cranking when the glow plugs preheat the combustion chambers. The time is automatically varied by the genset controller on the basis of engine temperature.) • Push and Release STOP (Prime) to stop the genset. • Push and Hold STOP (Prime) to prime the fuel system (amber lamp comes on in 2 seconds to indicate priming). Status Lamps: The control switch has two status lamps. The amber status lamp comes on during priming, blinks rapidly during cranking and goes out when the engine is up to speed. If the genset shuts down abnormally, this lamp will slowly blink a nu- merical code to indicate the cause of shutdown. See Troubleshooting (Section 5). The green status lamp comes on to indicate that the genset is running. Emergency Stop Switch: In an emergency push the switch to OFF . Push it to ON after all necessary repairs to the genset and connected equipment have been made. DC Circuit Breaker: This circuit breaker protects the DC control circuits of the genset from short circuits. Reset after all necessary repairs have been made to the genset. Hour Meter: The hour meter records genset operating time in hours. It cannot be reset. e-Series Digital Display Panel (Optional) The control panel may have an e-Series Digital Dis- play instead of a control switch. See Page 2-3 for details. SmartCraft is a trademark of the Brunswick Corporation. Downloaded from www.Manualslib.com manuals search engine

2-2 DC CIRCUIT BREAKER EMERGENCY STOP SWITCH EMERGENCY STOP SWITCH DC CIRCUIT BREAKER DIGITAL DISPLAY CONTROL SWITCH WITH STATUS LAMPS HOUR METER OPTIONAL DIGITAL DISPLAY PANEL STANDARD CONTROL SWITCH PANEL FIGURE 2-1. GENSET CONTROL PANEL Downloaded from www.Manualslib.com manuals search engine

Cummins Onan Marine Generator Set Service & Repair Manual

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