981-0524C Onan MDKAL MDKAA MDKAB Marine Diese Genset Service Manual

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Service Manual
MDKAL, MDKAA, MDKAB
Printed in U.S.A. 981−0524C

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
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Removing Genset from Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Powering Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Shore Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Resetting Line Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Genset Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Genset Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Returning Genset to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ENGINE (DC) CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1 Redistribution or publication of this document,

AUTOMATIC VOLTAGE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Adjusting Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Flashing the Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Testing AVR vs Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ADJUSTING THE FUEL STOP AND FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Stop (Except MDKAL Spec A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Frequency (Except MDKAL Spec A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fuel Stop (MDKAL Spec A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Frequency (MDKAL Spec A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine Does Not Stop Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Engine Does Not Crank from Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Does Not Crank from Genset Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Engine Cranks But Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Engine Starts But Does Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
“Check Engine” Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Engine Unstable or Lacks Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
No Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Faulty Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Output Voltage too High Or too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Unstable Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Unbalanced Phase Currents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
DC CONTROL SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
WIRING HARNESS DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
GENERATOR RECONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Safety Precautions
Thoroughly read the OPERATOR’S MANUAL • Used engine oil has been identified by some
before operating the genset. Safe operation and state and federal agencies as causing cancer
top performance can be obtained only by prop- or reproductive toxicity. Do not ingest, inhale,
er operation and maintenance. or contact used oil or its vapors.
The following symbols in this Manual alert you to • Do not work on the genset when mentally or
potential hazards to the operator, service personnel
and equipment. physically fatigued or after consuming alcohol
or drugs.
alerts you to an immediate hazard
which will result in severe personal injury or • Carefully follow all applicable local, state and
death. federal codes.
WARNING alerts you to a hazard or unsafe • Do not step on the genset, as when entering or
practice which can result in severe personal in- leaving the engine room. The stress can break
jury or death. genset parts leading to possible fuel or exhaust
leaks or electricution.
CAUTION alerts you to a hazard or unsafe
practice which can result in personal injury or GENERATOR VOLTAGE IS DEADLY!
equipment damage. • Generator output connections must be made
Electricity, fuel, exhaust, moving parts and batteries by a qualified electrician in accordance with ap-
present hazards which can result in severe person- plicable codes.
al injury or death. • The genset must not be connected to the public
GENERAL PRECAUTIONS utility or any other source of electrical power.
• Keep ABC fire extinguishers handy. Connection could lead to electrocution of utility
workers, damage to equipment and fire. An ap-
• Make sure all fasteners are secure and torqued proved switching device must be used to pre-
properly. vent interconnections.
• Keep the genset and its compartment clean. • Use caution when working on live electrical
Excess oil and oily rags can catch fire. Dirt and equipment. Remove jewelry, make sure cloth-
gear stowed in the compartment can restrict ing and shoes are dry and stand on a dry wood-
cooling air. en platform on the ground or floor.
• Let the engine cool down before removing the
FUEL IS FLAMMABLE AND EXPLOSIVE
coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray • Keep flames, cigarettes, sparks, pilot lights,
out and cause severe burns. electrical arc-producing equipment and
switches and all other sources of ignition well
• Before working on the genset, disconnect the
away from areas where fuel fumes are present
negative (- ) battery cable at the battery to pre-
and areas sharing ventilation.
vent starting.
• Fuel lines must be secured, free of leaks and
• Use caution when making adjustments while
separated or shielded from electrical wiring.
the genset is running—hot, moving or electri-
cally live parts can cause severe personal inju- • Use approved non-conductive flexible fuel
ry or death. hose for fuel connections at the genset.

ENGINE EXHAUST IS DEADLY! BATTERY GAS IS EXPLOSIVE
• Learn the symptoms of carbon monoxide poi- • Wear safety glasses and do not smoke while
soning in this manual. servicing batteries.
• Never sleep in the vessel with the genset run- • When disconnecting or reconnecting battery
ning unless the vessel is equipped with a work- cables, always disconnect the negative (- ) bat-
ing carbon monoxide detector. tery cable first and reconnect it last to reduce
arcing.
• The exhaust system must be installed in accor-
dance with the genset Installation Manual and DO NOT OPERATE IN FLAMMABLE AND
be free of leaks. EXPLOSIVE ENVIRONMENTS
• Make sure the bilge is adequately ventilated Flammable vapor can cause a diesel engine to
with a power exhauster. overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
MOVING PARTS CAN CAUSE SEVERE death. Do not operate a diesel-powered genset
PERSONAL INJURY OR DEATH where a flammable vapor environment can be
• Do not wear loose clothing or jewelry near mov- created by fuel spill, leak, etc., unless the gen-
ing parts such as PTO shafts, fans, belts and set is equipped with an automatic safety device
pulleys. to block the air intake and stop the engine. The
owners and operators of the genset are solely re-
• Keep hands away from moving parts.
sponsible for operating the genset safely. Contact
• Keep guards in place over fans, belts, pulleys, your authorized Onan/Cummins dealer or distribu-
etc. tor for more information.
POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE VESSEL

m-9

Specifications
MDKAL (Spec A) MDKAL (Spec B)
GENERATOR: Single-Bearing, 4-Pole Rotating Field, Brushless, Electronically Regulated. See Genset Namplate for Rating.
FUEL CONSUMPTION:
60 Hz: Full Load 0.8 gph (3.0 liter/hr) 0.8 gph (3.0 liter/hr)
Half Load 0.5 gph (1.8 liter/hr) 0.5 gph (1.9 liter/hr)
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection Diesel, Water Cooled, Mechanically Governed (5% droop)
Model D1005 D1105
Number of Cylinders 3 3
Bore / Stroke 2.99 inch (76 mm) / 2.90 inch (73.6 mm) 2.99 inch (76 mm) / 3.09 inch (78.4 mm)
Displacement 61 inch3 (1001 cm3) 68 inch3 (1124 cm3)
Compression Ratio 22:1 22:1
Firing Order (Clockwise Rotation) 1-2-3 1-2-3
Fuel Injection Timing 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC
0.0071 - 0.0087 inch 0.0071 - 0.0087 inch
Valve Lash (cold)
(0.18 - 0.22 mm) (0.18 - 0.22 mm)
Engine Oil Capacity 4.5 quart (4.3 liter) 4.2 quart (4.0 liter)
Engine Oil Drain Connection 3/8 NPT 3/8 NPT
Coolant Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter)
Coolant Flow Rate: 60 Hz 5.0 gpm (19 liter/min) 5.0 gpm (19 liter/min)
50 Hz 4.2 gpm (16 liter/min) 4.2 gpm (16 liter/min)
Sea Water Flow Rate: 60 Hz 6.0 gpm (23 liter/min) 6.0 gpm (23 liter/min)
Maximum Sea Water Pump Lift 4 feet (1.2 m) 4 feet (1.2 m)
Sea Water Inlet Connection 1.0 inch (25.4 mm) ID Hose 1.0 inch (25.4 mm) ID Hose
Maximum Fuel Pump Lift 4 feet (1.2 m) 4 feet (1.2 m)
Fuel Supply Connection 1/4 NPT female 1/4 NPT female
Fuel Return Connection 1/4 NPT female 1/4 NPT female
Maximum Exhaust Back Pressure 3 inch (76 mm) Hg 3 inch (76 mm) Hg
Wet Exhaust Outlet Connection 2.0 inch (50.8 mm) ID Hose 2.0 inch (50.8 mm) ID Hose
Dry Exhaust Outlet Connection 1-1/4 NPT 1-1/4 NPT
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts*, #
Minimum CCA Rating 360 amps 360 amps
Charging Alternator Output 35 amps 10 amps
APPROXIMATE WEIGHTS AND DIMENSIONS:
Without Sound Shield
Wet Weight 540 lbs (245 kg) 540 lbs (245 kg)
Dimensions: L x W x H 32.5x18.9x22.1 inch (826x479x562 mm) 32.5x18.9x22.1 inch (826x479x562 mm)
With Sound Shield
* - Isolated battery ground available as option.
# - 24 volt battery system available as option.

MDKAA MDKAB
GENERATOR: Single-Bearing, 4-Pole Rotating Field, Brushless, Electronically Regulated. See Genset Nameplate for Rating.
FUEL CONSUMPTION:
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection Diesel, Water Cooled, Mechanically Governed (5% droop)
Model V1305 V1505
Number of Cylinders 4 4
Bore / Stroke 2.99 inch (76 mm) / 2.90 inch (73.6 mm) 3.07 inch (78 mm) / 3.09 inch (78.4 mm)
Displacement 81.5 inch3 (1335 cm3) 91.4 inch3 (1498 cm3)
Compression Ratio 22:1 22:1
Firing Order (Clockwise Rotation) 1-2-4-3 1-2-4-3
Fuel Injection Timing 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC
0.0071 - 0.0087 inch 0.0071 - 0.0087 inch
Valve Lash (cold)
(0.18 - 0.22 mm) (0.18 - 0.22 mm)
Engine Oil Capacity 4.5 quart (4.3 liter) 4.5 quart (4.3 liter)
Engine Oil Drain Connection 3/8 NPT 3/8 NPT
Coolant Capacity 5.3 quart (5.0 liter) 5.3 quart (5.0 liter)
Coolant Flow Rate: 60 Hz 5.0 gpm (19 liter/min) 5.0 gpm (19 liter/min)
Sea Water Flow Rate: 60 Hz 6.0 gpm (23 liter/min) 6.0 gpm (23 liter/min)
Maximum Sea Water Pump Lift 4 feet (1.2 m) 4 feet (1.2 m)
Sea Water Inlet Connection 1.0 inch (25.4 mm) ID Hose 1.0 inch (25.4 mm) ID Hose
Maximum Fuel Pump Lift 4 feet (1.2 m) 4 feet (1.2 m)
Fuel Supply Connection 1/4 NPT female 1/4 NPT female
Fuel Return Connection 1/4 NPT female 1/4 NPT female
Maximum Exhaust Back Pressure 3 inch (76 mm) Hg 3 inch (76 mm) Hg
Wet Exhaust Outlet Connection 2.0 inch (50.8 mm) ID Hose 2.0 inch (50.8 mm) ID Hose
Dry Exhaust Outlet Connection 1-1/4 NPT 1-1/4 NPT
BATTERIES:
Nominal Battery Voltage 12 volts*, # 12 volts*, #
Minimum CCA Rating 500 amps 500 amps
Charging Alternator Output 10 amps 10 amps
APPROXIMATE WEIGHTS AND DIMENSIONS:
Without Sound Shield
With Sound Shield
* - Isolated battery ground available as option.
# - 24 volt battery system available as option.

Introduction
ABOUT THIS MANUAL
This is the Service Manual for the model MDKAL,
MDKAA and MDKAB generator sets (gensets). Ob-
serve carefully all of the instructions and precau- 10.5MDKAA/92989A
tions in this manual. A980123456
Operation, Periodic Maintenance Schedule and

Maintenance Procedures in the Operator’s Manual
have been duplicated here for your convenience.
The DC control schematic (Figure 25), the wiring
harness diagram (Figure 26) and the generator re- THIS ENGINE MEETS 1995-1998 CALIFORNIA
EMISSIONS REGULATIONS FOR ULGE ENGINES
connection diagrams (Figure 27) are in the back of SKB1.3U6D2RA
this manual for quick reference. If there is a conflict,
the schematic printed on the genset control box
cover takes precedence over the schematic in this
manual.
See the Installation Manual for important recom-
mendations and for a list of the installation codes
and standards for safety which may be applicable.
See the Parts Catalog for service part numbers.
See the Engine Workshop Manual for engine ser-
vice procedures. See Specifications in this manual
to determine the engine model.
WARNING Improper service or replacement of
parts can lead to severe personal injury or death FIGURE 1. TYPICAL NAMEPLATE
and damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.
CAUTION Unauthorized modifications or re-
placement of fuel, exhaust, air intake or speed
control system components that affect engine
emissions are prohibited by law in the State of
California.
MODEL IDENTIFICATION
When contacting Onan for parts, service or product
information, be ready to provide the model number
and the serial number on the genset nameplate.
See Figure 1.

FUEL RECOMMENDATIONS
High quality fuel is necessary for good performance
and long engine life. Use No. 2 diesel fuel
(ASTM 2-D) with a Cetane number of not less than
45 and sulfur content of not more than 0.5 percent
(by weight). Where fuel is exposed to cold ambient
temperatures, use fuel that has a cloud point (tem-
perature at which wax crystals begin to form) at
least 10 degrees below the lowest expected fuel
temperature.
WARNING Diesel fuel is combustible and can FIGURE 2. SAE VISCOSITY GRADE vs. AMBIENT
TEMPERATURE
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a type ABC
fire extinguisher handy.
ENGINE OIL RECOMMENDATIONS
Use premium quality motor oil. Look for the API
(American Petroleum Institute) classification and
use Class CG-4, CF-4, CF or better oil. Also look for
the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Figure 2, choose the viscos-
ity grade appropriate for the range of ambient tem-
peratures expected before the next scheduled oil
change. Multi-grade oils such as SAE 15W-40 are
recommended for year-round use.
BATTERIES
The genset requires either a 12 volt or 24 volt bat-
tery to power its control and starting circuits. Reli-
able genset starting and starter service life depend
upon adequate battery system capacity and main-
tenance. See Specifications for battery require-
ments.

SAFETY TABLE 1. HAZARDS AND THEIR SOURCES
There are hazards in servicing gensets. Study • Leaking or spilled fuel
Safety Precautions and become familiar with the
Fire and
• Hydrogen gas from battery
hazards listed in Table 1. Note the following safe- Explosion • Oily rags improperly stored
guards and ways of avoiding hazards: • Flammable liquids improperly
stored
• Use personal protection: Wear protective
safety equipment, such as safety shoes and • Hot exhaust pipes
Burns
• Hot engine and generator sur-
safety glasses. faces
Do not wear rings or jewelry and do not wear • Electrical shorts
loose or damp clothing that might get caught in Poisonous • Operating genset where ex-
equipment or conduct electricity. Gas haust gases can accumulate
• Reduce the hazard: A safe, orderly workshop • Improper generator connec-
area and well-maintained equipment reduce tions
the hazard potential. Keep guards and shields Electrical • Faulty wiring
in place on machinery and maintain equipment
Shock (AC) • Working in damp conditions
• Jewelry touching electrical
in good working condition. Store flammable liq- components
uids in approved containers; away from fire,
flame, spark, pilot light, switches, arc-produc- Rotating • Fan guards not in place
Machinery
ing equipment and other ignition sources. Keep
the workshop clean and well lighted and pro- Slippery • Leaking or spilled oil
Surfaces
vide adequate ventilation.
Heavy • Removing genset from vessel
• Develop safe work habits: Unsafe actions Objects • Removing heavy components
cause accidents with tools and machines. Be
familiar with the equipment and know how to
use it safely. Use the correct tool for the job and
check its condition before starting. Comply with
the warnings in this manual and take special
precautions when working around electrical
equipment. Do not work alone, if possible, and
do not take risks.
• Be prepared for an accident: Keep fire extin-
guishers and safety equipment nearby. Agen-
cies such as the Red Cross and public safety
departments offer courses in first aid, CPR and
fire control. Take advantage of this information
to be ready to respond to an accident. Learn to
be safety-conscious and make safety proce-
dures part of the work routine.

SERVICE TOOLS 1. Battery cables (negative [- ] cables first).
The following special tools are necessary: WARNING Arcing at battery terminals or in
• Torque wrench: 0-75 lbs-ft (0-100 N-m) a light switch or other equipment, flames
and sparks can ignite battery gas causing
• Tachometer or frequency meter severe personal injury. Ventilate the battery
• Digital multi-meter: AC and DC Volts, Ohms compartment before connecting or discon-
necting battery cables—Disconnect the
• Load test panel, leads and ammeter
negative (-) cable first and reconnect it
• 500 VDC Megger for winding insulation resist- last—Wear safety glasses—Do not
ance measurements smoke—Switch lights ON and Off away
• 0.01 ohm precision digital ohmmeter or Wheat- from the battery.
stone bridge for winding resistance measure- 2. Fuel lines. First close all fuel shutoff valves.
ments
WARNING Diesel fuel is combustible and
• AVR/Generator test adapter (p. 29) can cause severe personal injury or death.
REMOVING GENSET FROM VESSEL Do not smoke near fuel tanks or fuel-burn-
ing equipment or in areas sharing ventila-
Contact the manufacturer of the vessel or the in-
tion with such equipment. Keep flames,
staller if a good way to remove the genset is not ob-
sparks, pilot flames, electrical arcs and
vious. There are four bolt holes for securing the
switches and all other sources of ignition
genset to the floor or supporting structure of the
well away. Keep a type ABC fire extinguish-
vessel. A lifting eye is accessible through the ac-
er handy.
cess opening in the top panel of the sound shield.
3. Remote control wiring.
WARNING Gensets are heavy and can cause
severe personal injury or death if dropped. Use 4. AC output wiring.
adequate lifting devices and keep hands and 5. Exhaust hose.
feet clear while lifting.
6. Sea water supply hose (first close sea cock).
The following disconnections will have to be made
to remove the genset from the vessel: 7. Coolant hoses to a keel cooler (if provided).

Operation
EXHAUST GAS IS DEADLY!
Engine exhaust contains carbon monoxide, a poisonous, odorless and colorless gas that can
cause unconsciousness and death. Symptoms of carbon monoxide poisoning include:
• Dizziness • Throbbing in Temples • Nausea
• Muscular Twitching • Headache • Vomiting
• Weakness • Trouble Thinking Clearly • Sleepiness
GET EVERYONE OUT INTO FRESH AIR IMMEDIATELY IF ANYONE EXPERIENCES ANY OF
THESE SYMPTOMS. Seek medical attention if symptoms persist.
Never sleep in the vessel when the genset is running unless the cabins have operating carbon
monoxide detectors.
Look and listen for leaks along the entire run of the exhaust system every time you start up the
genset and every eight hours if the genset is being run continuously. Shut down the genset
immediately if there is a leak and do not run it until the leak has been repaired.
The installation of the exhaust system must be in accordance with the genset Installation
Manual.
PRE-START CHECKS Troubleshooting if the engine does not start on

the second try.
Perform the GENERAL INSPECTION (p. 16).
Check for fuel, exhaust, oil and coolant leaks CAUTION Excessive cranking can over-
every eight hours if the genset is being run con- heat and damage the starter. Do not crank
tinuously. for more than 20 seconds at a time and wait
Check the maintenance record and perform any two minutes before trying again.
maintenance due (Periodic Maintenance Sched- 4. Connect the electrical loads after the genset
ule). Also see GENSET BREAK-IN in this section if has warmed up for a few minutes.
the genset is new and RETURNING THE GENSET 5. Check for fuel, exhaust, oil and coolant leaks
TO SERVICE if the vessel has been in storage. and complete the GENERAL INSPECTION
STARTING (p. 16). Check the engine gauges regularly (if
provided).
1. Disconnect all loads from the genset.
• Oil Pressure Gauge: Normal engine oil
2. Preheat - Hold the control switch in the PRE- pressure is 28 - 64 psi (194 - 442 kPa) at
HEAT position for 5 to 20 seconds.
normal operating temperature.
CAUTION Preheat times longer than 20
• DC Voltmeter: Normal DC system voltage
seconds can damage the glow plugs. is 12.5 - 15 volts (12 volt system) or
3. Start - Immediately after PREHEAT push the 24 - 27 volts (24 volt system) depending
control switch to START and hold it there until on battery condition and state-of-charge.
the engine starts. The starter will automatically • Coolant Temperature Gauge: Normal
disconnect as the engine starts up. engine coolant temperature is
Do not crank for more than 20 seconds at a 160 -195° F (71 - 91° C) depending on
time. Wait two minutes before trying again. See sea water* temperature and load.
* In this manual, “sea water” refers to floatation water.

STOPPING TABLE 2. TYPICAL APPLIANCE LOADS
Before stopping let the genset cool down by run- Appliance Load (watt)
ning at no-load for three to five minutes. Then touch Air Conditioner 1400-2000
the control switch momentarily to STOP.
Battery Charger Up to 800
CAUTION Failure to let the engine cool down
DC Converter 300-1500
before stopping can lead to engine damage. Let
the genset run three to five minutes at no-load Refrigerator 600-1000
before stopping. Microwave Oven 1000-1500
POWERING APPLIANCES Electric Frying Pan/Wok 1000-1500
The genset can power AC motors, air conditioners, Electric Stove Element 350-1000
AC/DC converters and other appliances. How Electric Water Heater 1000-1500
much appliance load* can be serviced depends Electric Iron 500-1200
upon the genset power rating. The genset will shut
down or its circuit breakers will trip if the total load Electric Hair Dryer 800-1500
exceeds genset rating. Coffee Percolator 550-750
To avoid overloading the genset and causing shut- Television 200-600
downs, compare the sum of the loads of the ap- Radio 50-200
pliances that are likely to be used at the same time
(total load) to the power rating of the genset. Use Electric Drill 250-750
Table 2 or the ratings on the appliances themselves Electric Broom 200-500
(if so marked) to obtain the individual appliance Electric Blanket 50-200
loads. It may be necessary to run fewer ap-
pliances at the same time so that the total load is
not greater than genset rating.
Note that the genset may shut down due to over-
load, even though the total load is less than genset
rating, when a large motor or air conditioner is
started last or cycles off and then on again. The rea-
son for this is that motor startup load is much larger
than running load. It may be necessary to run few-
er appliances when large motors and air condi-
tioners are cycling on and off.
SHORE POWER CONNECTIONS
A vessel that has provisions for connection to shore
power must be equipped with an approved transfer
switch to keep the genset and shore power from be-
ing interconnected.
WARNING Backfeed to shore power can cause
electrocution and damage to equipment. Use an
approved device to prevent the genset from be-
ing interconnected with shore power.
* Appliance load and genset power are measured in terms of watt (W) or kilowatt (kW), where 1 kilowatt (kW) = 1000 watt (W).

RESETTING LINE CIRCUIT BREAKERS
CIRCUIT BREAKERS
If a circuit breaker in the main power distribution
panel in the vessel or on the genset (Figure 3) trips,
there is either a short circuit or too much load. Note
that the genset will continue to run after a circuit
breaker trips.
If a circuit breaker trips, disconnect or turn off as
many appliances as possible and reset the circuit
breaker. (Push the circuit breaker OFF to reset it
and then ON to reconnect the circuit.) If the circuit
breaker trips right away, either the electrical dis-
tribution system has a short or the circuit breaker is
faulty. Call a qualified electrician.
If the circuit breaker does not trip, reconnect a com-
bination of appliances that does not overload the
genset or cause the circuit breaker to trip. An ap-
pliance that causes a circuit breaker to trip right
away probably has a short.
Electrical appliances must be properly grounded
and in good working condition.
WARNING Electrical shock can cause severe FIGURE 3. GENSET MOUNTED LINE CIRCUIT
personal injury or death. Read and follow the BREAKERS
appliance manufacturer’s instructions and
warnings.
ENGINE BREAK-IN
Change the oil and oil filter after the first 35 hours of
operation. See Maintenance Procedures.
NO-LOAD OPERATION
Keep no-load operation to a minimum. During
no-load operation combustion chamber tempera-
tures drop to the point where fuel does not burn
completely, causing slobbering and white smoke.
Always have some load connected when the gen-
set is run for long periods.

GENSET EXERCISE dance with the manufacturer’s recommenda-
tions.
If use is infrequent, run the genset at approximately
1/2 rated power for an hour every week. Exercising WARNING Hot coolant is under pressure
the genset results in better starting, longer engine and can cause severe burns when loosen-
life and increased genset reliability by driving off ing the pressure cap. Let the engine cool
moisture, re-lubricating the engine, using up fuel before loosening the pressure cap.
before it becomes stale and removing oxides from 4. Check the coolant level and add coolant as
electrical contacts. One longer period during which necessary. Test the coolant mixture if freezing
the engine and generator warm up thoroughly is temperatures are possible and change if nec-
better than several shorter periods. essary. See ENGINE COOLING SYSTEM in
GENSET STORAGE Maintenance Procedures.
If the genset will be inactive for more than 30 days 5. If freezing temperatures are possible, drain the
and it is impractical to have someone exercise it, heat exchanger of sea water by removing the
prepare it for storage as follows: drain plug in the bottom of the heat exchanger
(Figure 5). Replace the plug when the water
1. Run the genset until it has thoroughly warmed has drained.
up and shut it down.
6. Clean the genset and lightly oil parts that can
WARNING Crankcase pressure can blow rust.
out hot oil and cause severe burns. Stop the
RETURNING GENSET TO SERVICE
engine before checking the oil level or
opening the fill cap. 1. Check the tag on the dipstick and change the
oil if the viscosity is not suitable for present and
2. Change the oil and oil filter while still warm and
anticipated ambient temperatures.
attach a tag to the dip stick indicating the oil vis-
cosity grade. See CHANGING OIL AND OIL 2. Reconnect the battery(ies) (negative [- ] cables
FILTER in Maintenance Procedures. last) and service as necessary in accordance
with the manufacturer’s instructions.
WARNING Arcing at battery terminals or in
a light switch or other equipment, flames 3. Prime the fuel system (p. 24).
and sparks can ignite battery gas causing 4. Replace the sea water pump impeller if it was
severe personal injury. Ventilate the battery installed more than a year ago. If less, remove
compartment before connecting or discon- the impeller cover and wet the internal surfaces
necting battery cables—Disconnect the of the pump with water to establish initial lu-
negative (-) cable first and reconnect it brication and pump suction. See Replacing the
last—Wear safety glasses—Do not Sea Water Pump Impeller (p. 22).
smoke—Switch lights ON and Off away
5. Perform PRE-START CHECKS and start and
from the battery.
run the genset according to STARTING. Per-
3. Disconnect the battery cables (negative [- ] form maintenance or service as required be-
cables first) and store the battery(ies) in accor- fore placing the genset in service.

Periodic Maintenance Schedule
Periodic maintenance is essential for top genset WARNING Accidental starting can cause se-
performance and long service life. Use Table 3 as a vere personal injury or death. Disconnect the
guide and follow the Maintenance Procedures. negative (-) cable(s) at the battery(ies) to pre-
vent starting while working on the genset.
TABLE 3. PERIODIC MAINTENANCE SCHEDULE
FREQUENCY
P
After Every Every Every 6 Every a
first Day/ Month/ Months/ Year/ Every Every Every g
PROCEDURE 35 Hrs 8 Hrs 100 Hrs 200 Hrs 500 Hrs 800 Hrs 2 years 5 years e
Inspect Genset x1 16
Check Oil Level x 16
Check Coolant Level x 16
Check Fuel Level x 16
Check Exhaust System x 16
Check Battery x2 -
Check V-Belt Tension x3 20
Drain Water in Fuel x 23
Check Siphon Break x 21
Clean Genset x 16
Change Oil & Oil Filter x x 17
Change Fuel Filter x 23
Change Zinc Anode x 21
Replace Sea Water Im-
x 22
peller
Check Generator Bear-
x4 -
ing
Adjust Valve Lash x4 -
Change Coolant, Pres-
sure Cap, Thermostat, x 18
Hoses, V-belt
Replace Generator
x4 -
Bearing
1 - Check for oil, fuel, coolant and exhaust system leaks.
2 - See battery manufacturer’s recommendations.
3 - Check for slippage.
4 - Must be performed by an authorized Onan dealer. Check every year for evidence of outer race rotation.

Maintenance Procedures
GENERAL INSPECTION Exhaust System Inspection
Perform these checks and inspections every time Wet Exhaust System: Inspect the exhaust system
the genset is started or every eight hours if the gen- for leaks and loose hose clamps at the exhaust
set is being run continuously. manifold, exhaust elbow, muffler, water separator
and hull fittings. Replace damaged sections of ex-
Oil Level Check haust hose.
WARNING Crankcase pressure can blow out Dry Exhaust System: Inspect the exhaust system
hot oil and cause severe burns. Stop the engine for leaks at all joints, welds and gaskets. Replace
before checking the oil level or opening the fill rusted sections of exhaust pipe.
cap. WARNING EXHAUST GAS IS DEADLY! Do not
Shut down the genset to check engine oil level and
operate the genset until all exhaust leaks have
wait a few minutes for the oil to drain down to the
been repaired.
crankcase to get an accurate indication of oil level. Fuel System Inspection
Keep the oil level between FULL and ADD on the Check for leaks at all fuel line fittings and gaskets.
dipstick (Figure 4). See ENGINE OIL REC- Replace fuel hose that has been abraded or cut and
OMMENDATIONS in Introduction for the type of oil install new hose in such a way that it will not become
to add. kinked, rub against other parts or come in contact
with sharp edges, hot surfaces or wiring.
CAUTION Too little oil can lead to severe en-
gine damage and too much oil to high oil con- WARNING Fuel leaks can lead to fire. Repair
sumption and foaming, which can cause engine leaks immediately. Do not run the genset if there
shutdown. Keep the oil level between FULL and is a fuel leak.
ADD. Prime the fuel system if the genset ran out of fuel or
a fuel filter was replaced. See FUEL SYSTEM.
Coolant Level Check
Battery Inspection
Replenish the normal loss of coolant by keeping the
level in the coolant recovery tank between COLD Check for clean, tight battery connections. Loose-
and HOT. See COOLING SYSTEM for the recom- ness and corrosion cause high electrical resist-
mended mixture of antifreeze. ance, which makes for hard starting.
WARNING Arcing at battery terminals or in a
Sea Water Pump, Strainer and Sea Cocks
light switch or other equipment, flames and
Clean out the sea water strainer if necessary and sparks can ignite battery gas causing severe
make sure the sea cock is open. When a water sep- personal injury. Ventilate the battery compart-
arator is part of the exhaust installation make sure ment before connecting or disconnecting bat-
the exhaust water sea cock is open. tery cables—Disconnect the negative (-) cable
first and reconnect it last—Wear safety
If the sea water pump is located higher than the load glasses—Do not smoke—Switch lights ON and
waterline and it has been a week or more since the Off away from the battery.
genset has been run, it is recommended that the im-
peller cover be removed and the internal surfaces of Mechanical Inspection
the the pump be wetted with water to establish initial Check for unusual noises and vibrations, loose gen-
lubrication and pump suction. See Replacing the set mounts and signs of mechanical damage.
Sea Water Pump Impeller (p. 22). Check the engine gauges regularly (if provided).
See Operation for normal gauge readings.
CAUTION Wet the internal surfaces of the
pump as often as necessary to prevent dry Keep the genset clean. Do not clean the genset
startups, which severely shorten impeller life. while it is running. Protect the generator, control

panel, and electrical connections from cleaning sol- storage position. Two wrenches are necessary to
vents. keep from twisting the hose when removing and
tightening the plug.
CHANGING OIL AND OIL FILTER
WARNING State and federal agencies have de- Changing Oil Filter: To change the oil filter, place a
termined that contact with used engine oil can container under the oil filter (Figure 4) to catch oil
cause cancer or reproductive toxicity. Take care that drips out and then spin off the oil filter. Clean the
to limit skin contact and breathing of vapors. filter mounting surface, apply oil to the new filter
Use protective gloves and wash exposed skin. gasket and spin the filter on until the gasket just
touches the mounting pad. Then tighten an addi-
Table 3 specifies the maximum intervals for oil and tional 3/4 turn.
oil filter change. See ENGINE OIL RECOMMEN-
DATIONS in Introduction for the oil to use and Spec- Refilling Engine Oil: Refill with the proper amount
ifications for the amount. of oil, start the engine and check for leakage around
the filter gasket. Tighten the filter only enough to
WARNING Crankcase pressure can blow out stop leakage. Shut off the genset, recheck the oil
hot oil and cause severe burns. Stop the engine level and add oil as necessary.
before checking the oil level or opening the fill
cap. CAUTION Too little oil can lead to severe en-
gine damage and too much oil to high oil con-
Draining Engine Oil: To drain the engine oil, run
sumption and foaming, which can cause engine
the engine until thoroughly warm and then stop it. If
shutdown. Keep the oil level between FULL and
an oil pump-out system is installed, follow the in-
ADD.
structions provided. If not, unscrew the plug on the
end of the drain hose (Figure 4) and drain the oil into Disposing of Used Oil and Oil Filter: Dispose of
a suitable container. When the oil is completely the used oil and oil filter according to local environ-
drained, reinstall the plug and return the hose to its mental regulations.
OIL DIPSTICK OIL FILL
OIL DRAIN HOSE OIL FILTER
FIGURE 4. OIL CHECK, FILL, DRAIN AND FILTER

ENGINE COOLING SYSTEM Changing Coolant
Table 3 specifies the maximum intervals for replac- WARNING Hot coolant is under pressure and
ing coolant, hoses, pressure cap, thermostat, V-belt can cause severe burns when loosening the
and zinc anode. pressure cap. Let the engine cool before loos-
ening the pressure cap.
Cooling System Overview
WARNING Accidental starting can cause se-
The engine is cooled by a pressurized, closed-loop vere personal injury or death. Disconnect the
liquid cooling system. Coolant is pumped through negative (-) cable(s) from the battery(ies) to pre-
passages in the engine block, head and exhaust vent the engine from starting.
manifold and is cooled in a genset-mounted heat Draining the System: Let the engine cool down,
exchanger or keel cooler. The V-belt drives the en- disconnect the negative (- ) cable(s) at the bat-
gine coolant pump. tery(ies) to prevent the engine from starting, re-
If the genset has a heat exchanger and/or a wet ex- move the system pressure cap and open the block
haust elbow, the engine is equipped with a sea wa- and heat exchanger drain cocks (Figure 5). See the
ter* pump driven by a power takeoff on the engine. manufacturer’s instructions regarding a keel cooler.
The sea water cools the heat exchanger and/or ex- Collect used coolant in containers for proper dis-
haust gases and exits the vessel through the ex- posal.
haust system. (There is no sea water pump if the WARNING Ethylene glycol antifreeze is toxic.
genset is equipped for keel cooling and dry ex- Keep away from children and animals and dis-
haust.) Figure 5 illustrates a typical installation of a pose of according to the local regulations for
genset equipped with a heat exchanger, wet ex- hazardous substances.
haust elbow and sea water pump.
Cleaning and Flushing the System: Use radiator
Recommended Coolant Mixture cleaning chemicals to clean and flush the cooling
system before new coolant is added. Follow the
Use the best quality ethylene or propylene glycol manufacturer’s instructions.
antifreeze solution available. It should be fully for-
CAUTION Filling a hot engine with cold water
mulated with rust inhibitors and coolant stabilizers
can cause cracks in the manifold, head and
but not with stop-leak additives. Use fresh water
block. Follow the manufacturer’s instructions
that is low in minerals and corrosive chemicals. Dis-
for cleaning and flushing.
tilled water is best. Unless prohibited by shipping
regulations, gensets with heat exchangers are Filling the System: Close all drain cocks and se-
shipped with the recommended 50/50 mixture of cure all hose clamps and fill the system through the
water and ethylene glycol, which is good for -34° F fill opening. The system will fill only as fast as the air
(-37° C). can escape. Fill to the bottom of the fill neck. Start
and run the engine until it warms up (thermostat
See Specifications for coolant system fill capacity if opens) to dislodge air pockets and shut it down. Add
the genset is equipped with a heat exchanger. If the as much coolant as necessary and secure the pres-
genset is keel cooled, system capacity also de- sure cap.
pends on the capacity of the keel cooler.
CAUTION Low coolant level can cause severe
Coolant Recovery Tank engine damage. Make sure the system is full.
Replenish the normal loss of coolant by keeping the Pressure Cap

level in the recovery tank between COLD and HOT. Replace the pressure cap periodically (Table 3) to
Use the recommended mixture of antifreeze. See maintain optimal engine cooling and minimal cool-
Changing Coolant if it is necessary to fill the system. ant loss.
* In this manual, “sea water” refers to floatation water.

COOLANT RECOVERY TANK COOLANT PRESSURE CAP HIGH EXHAUST TEMPERATURE CUT
(REFILL NORMAL COOLANT LOSS HERE) (REFILL SYSTEM HERE) OFF SWITCH ON EXHAUST ELBOW
DRAIN TUBE
(ROUTE TO DRIP PAN)
SEA WATER
HOSE
SEA WATER COOLED

HEAT EXCHANGER COOLANT
HOSES
CLEANOUT
COVER
COOLANT DRAIN
COOLANT SEA WATER
SEA WATER (TO CLOSE)
COOLANT
CLEANOUT
COVER
COOLANT DRAIN
(TO CLOSE)
ZINC SEA WATER

ANODE DRAIN
TO HEAT THERMOSTAT V−BELT SEA WATER SEA COCK

EXCHANGER HOUSING GUARD STRAINER
SEA WATER HULL

STRAINER
(SLOTS PARALLEL
TO KEEL)
SEA WATER
PUMP
FIGURE 5. TYPICAL HEAT EXCHANGER-TYPE COOLING SYSTEM

Adjusting V-Belt Tension
ADJUSTING
The V-belt (Figure 6) drives the coolant pump and BRACKET
battery charging alternator. BOLT

vere personal injury or death. Disconnect the
negative (-) cable(s) at the battery(ies) to pre-
vent the engine from starting.
PIVOT
1. Disconnect the negative (- ) cable(s) at the bat- BOLT
tery(ies) to prevent the engine from starting
and remove the belt guard or sound shield
door.
2. Loosen the alternator pivot bolt first and then

the adjusting bracket bolt on top.
3. Tighten belt tension by pivoting the alternator

outwards. Hold tension by tightening the ad-
justing bracket bolt. Apply 20 pounds (10 kg) as
shown to the middle of the pulley span and
measure belt deflection, which should be 0.4
0.4 INCH (10 MM)
inch (10 mm). Tighten the alternator bolts DEFLECTION AT
when tension is correct. 20 LBS (10 KG)
4. Secure the belt guard or sound shield door and

reconnect the battery cables (negative [- ] FIGURE 6. ADJUSTING V-BELT TENSION
last).
Replacing Thermostat
Replace the thermostat periodically (Table 3) to
maintain optimal engine cooling.

vere personal injury or death. Disconnect the
vent the engine from starting.
WARNING Hot coolant is under pressure and

can cause severe burns when loosening the
pressure cap. Let the engine cool before loos- THERMOSTAT
ening the pressure cap.
1. Let the engine cool, loosen the pressure cap
and disconnect the negative (- ) cable(s) at the
battery(ies) to prevent the engine from starting.
2. Remove the two thermostat housing bolts (Fig-

ure 7) and pull off the housing, thermostat and
gasket. The hose does not need to come off.
3. Clean off the gasket area and reassemble as

shown with the new thermostat and gasket. Ap-
ply Three Bond 1215 liquid sealant or equiva-
lent to the top side of the gasket. FIGURE 7. REPLACING THERMOSTAT

Heat Exchanger and Zinc Anode If of the spring-loaded valve design, check for free
movement of the plunger. Replace the device if the
The heat exchanger has cleanout covers on both plunger does not move freely or the body is en-
ends to clean the sea water tubes. Remove the cov- crusted with deposits from leakage past the valve
ers to clean out seaweed and pump debris. If nec- seat.
essary, take the heat exchanger to a radiator shop If of the bleed-vent type (Figure 8), check that the
for chemical cleaning of hard deposits. vent hose is properly connected on both ends. If the
vent is connected to a hull fitting, check for normal
Siphon Break water flow whenever the engine is running.
A siphon break is installed when the exhaust elbow WARNING Bypassing a siphon break or failing
is below, or less than 6 inches (152 mm) above, the to maintain it can lead to engine flooding and
load waterline (Figure 8) to prevent flooding when damage to the engine not covered under War-
the engine is not running. ranty.
12 INCH (305 MM) MINIMUM HEIGHT OF SIPHON BREAK VENT LINE CONNECTED TO THIS RE-
SIPHON BREAK ABOVE LOAD WATERLINE GION OF EXHAUST TUBE OR TO HULL FITTING.
VENTED
SIPHON
BREAK
LOAD WA-
TERLINE
A SIPHON BREAK IS REQUIRED WHEN MUFFLER

THE EXHAUST ELBOW OUTLET IS BELOW
OR LESS THAN 6 INCHES (152 MM)
ABOVE THE LOAD WATERLINE
FIGURE 8. TYPICAL INSTALLATION OF A VENT-TYPE SIPHON BREAK AND WET EXHAUST SYSTEM

Replacing the Sea Water Pump Impeller
The sea water pump (Figure 9) is driven off a power
takeoff on the engine. To replace the impeller: COVER O-RING
1. Disconnect the negative (- ) cable(s) at the bat-

tery(ies) to prevent the engine from starting.
WARNING Accidental starting can cause
FLEXIBLE
severe personal injury or death. Discon- IMPELLER
nect the negative (-) cable(s) at the bat-
tery(ies) to prevent the engine from start-
ing.
2. Close the sea cock and remove the impeller
cover and O-ring.
3. Using two pairs of pliers to grip vanes on oppo-
site sides, pull out the old impeller. Check for TO HEAT EX-
CHANGER
and cleanout pieces of the impeller from the OR EXHAUST
heat exchanger and exhaust elbow if vanes ELBOW
have broken off.
4. Install the new impeller. It helps to twist the im- FROM
peller clockwise while squeezing it into the SOURCE
housing. Push it in all the way when the keyway
lines up with the key in the shaft. The vanes
should all incline backwards, that is, counter-
clockwise; the impeller turns clockwise. IMPELLER ROTATION
AND VANE INCLINATION
5. 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 and secure
the O-ring and cover.
CAUTION Do not lubricate with petroleum
products like grease and oil which chemi-
cally attack impeller materials.
6. If the sea water strainer is above the waterline,
remove the strainer element cover, fill it with
water (which also fills the hose to the pump) FIGURE 9. REPLACING SEA WATER PUMP IMPEL-
and reinstall the cover. LER
7. Open the sea cock, reconnect the battery
cables (negative [- ] last) and start the genset.
Shut down the genset within 30 seconds if
there is no water flow from the exhaust hull fit-
ting. (Flow will not be visible if an exhaust water
separator has been installed. In that case, feel
the pump cover and shut down the genset if the
pump gets hot.) If there is no flow, find and re-
move the blockage before the genset is started
again.
WARNING The pump gets hot quickly if
there is no flow and can burn your fingers.
Be cautious when touching the pump.

FUEL SYSTEM tion cannot be avoided. To drain the filter, remove
the plug (Figure 10), collect the water and sediment
Fuel Handling Precautions (about 1/2 cup [120 ml]) in a suitable container and
Keep dirt, water and other contaminants from enter- dispose of properly. Reinstall the plug securely.
ing the fuel system and damaging, corroding or
clogging fuel injection components. The genset has Replacing the Filter Element: See Table 3 for the
a water-separator type of fuel filter but the fuel sup- regular frequency of fuel filter change. Replace the
ply system should have a filter and water separator filter sooner if the engine lacks power or surges.
installed ahead of connections at the genset. 1. Drain the filter as explained above and spin off
A primary source of water in fuel, which can clog fuel the element.
passages by freezing and cause corrosion by form- 2. Clean the contact surface of the base.
ing sulfuric acid with the sulfur in the fuel, is the con-
densation of humid air on the walls of the fuel tank. 3. Lubricate the new element and its gasket, and
Keeping fuel tanks as full as possible reduces con- fill the element with clean diesel fuel.
densation by reducing the area on which condensa- 4. Spin the new element onto the base and hand
tion can take place. tighten.
Fuel Filter 5. Start and run the genset and check for fuel
Draining Water and Sediment: See Table 3 for the leakage. Tighten the filter only enough to stop
regular frequency of draining water and sediment. leakage. See Priming the Fuel System if the
Drain more often if fuel quality is poor or condensa- genset does not start.
FUEL STOP SOLENOID FUEL INJECTION PUMP
FUEL CONNECTIONS FUEL PUMP FUEL FILTER DRAIN PLUG FUEL FILTER
FIGURE 10. FUEL SYSTEM

Priming the Fuel System Priming the High-Pressure Side: This procedure
should only be performed by a diesel mechanic.
Priming the Low-Pressure Side: The fuel lift
WARNING The high pressure oil spray from an
pump (Figure 10) primes during preheat when the
control switch is held in the stop position. Priming injector line fitting can penetrate the skin, lead-
purges air from the low-pressure side of the fuel in- ing to possible blood poisoning. Wear safety
jection system. glasses and keep your hands away from the
spray. Do not delay getting proper medical
CAUTION Preheating for more than 20 sec- attention if oil spray penetrates your skin.
onds at a time reduces the life of the glow plugs. 1. Loosen the high pressure fittings at the
Let the glow plugs cool for at least one minute nozzles. Use two wrenches to keep from twist-
before trying again. ing the return fittings. Use flare-nut wrenches
to keep from rounding the shoulders.
If priming for 20 seconds at a time is not enough,
open the bleed screw and disconnect the engine 2. Crank the genset until fuel appears at the loos-
harness lead from the glow plugs (Figure 11) and ened fittings and then snug up each fitting. The
make sure it cannot ground on the block. Then engine should start and run when the first fitting
press STOP until fuel just starts to appear at the is snugged.
bleed opening. Tighten the bleed screw and recon- 3. Shut down the engine and torque the fittings to
nect the lead to the glow plugs. 19 - 25 lb-ft (25 - 34 N-m).
TO PRIME MORE THAN 20 SECONDS DISCONNECT ENGINE

HARNESS FROM THIS GLOW PLUG TERMINAL AND
INSULATE END
USE TWO FLARE−NUT WRENCHES TO

LOOSEN THESE FITTINGS TO BLEED HIGH
PRESSURE INJECTOR LINES
WEAR SAFETY GLASSES AND KEEP
FINGERS OUT OF SPRAY
AVOID LOOSENING
THESE FITTINGS
OPEN LOW−PRESSURE BLEED

USE TWO WRENCHES SO AS NOT TO
LOOSEN FUEL FITTING
FIGURE 11. PRIMING THE FUEL SYSTEM

Engine (DC) Control
See Figures 12 and 13 to locate the control compo-
nents on the control panel and inside the control
box. See Figure 14 to locate the control compo-
nents mounted on the engine, such as the fuel stop S6
solenoid, gauge senders and shutdown switches. OIL
COOLANT DC
Figures 25 and 26 at the back are the control sche- PRESS TEMP VOLTAGE
M4
M2 M3
matic and connection diagrams.
CONTROL PANEL CB1
CB5 CB2
Start-Stop-Prime/Preheat Switch (S1): Starts the M1 S1
genset when held at Start and stops the genset CB4
when momentarily touched to Stop. Holding the

switch at Stop causes the glow plugs to preheat the
combustions chambers and the fuel lift pump to
prime the fuel system. FIGURE 12. CONTROL PANEL
Hour Meter (M1): Indicates the number of hours

the genset has run. It cannot be reset.
Engine Gauges (M2, M3, M4): Optional—indicate
engine oil pressure, coolant temperature and con-
trol system DC voltage. If remote gauges have been
installed, push gauge switch (S6) in to read M2 and
M3 at the genset.
Gauge Switch (S6): Momentary contact switch
used only when remote gauges have been
installed. Push the button to read M2 and M3 at the
genset.
“Check Engine” Fault Breaker (CB2): Shuts
down the genset when one of the following fault
conditions causes it to trip: over/undervoltage, over/
underspeed, low oil pressure, high exhaust temper-
ature, high coolant temperature and low coolant
level (optional). Push the reset button to reset.
“Check Generator” Fault Breaker (CB5): Shuts
down the genset when high generator quadrature
winding current causes it to trip. Push the reset but- FIGURE 13. CONTROL BOX
ton to reset.
DC Circuit Breaker (CB1): Protects the high-cur-
rent (DC) glow plug circuits from shorts to ground.
The genset will stop if tripped. Reset with handle.
Emergency Stop Breaker (CB4): A rocker switch
type of circuit breaker that protects the genset con-
trol circuits (DC) from shorts to ground. The genset
will stop if the circuit breaker trips or the rocker is
pushed to Stop. Push the rocker On to reset.

CONTROL FUEL STOP GLOW PLUGS OIL PRESSURE COOLANT
PANEL SOLENOID (BEHIND INJECTORS) SWITCH GAUGE SENDER
K7 HR1,2,3,4 S4 E2
OIL GAUGE
SENDER
E1
OIL FILL
COMBUSTION
AIR INLET
SEA
WATER
OIL
FILTER
FUEL OIL DRAIN OIL FUEL PUMP FUEL SEA WATER

CONNECTIONS TUBE DIPSTICK E5 FILTER INLET
BATTERY HIGH COOLANT COOLANT LOW COOLANT HIGH EXHAUST

CHARGING TEMP SWITCH PRESSURE CAP LEVEL SWITCH TEMP SWITCH
ALTERNATOR S2 S3 S5
G1
AC OUTPUT BOX
BLOCK AND LINE CIRCUIT
DRAIN BREAKERS
SEA
COOLANT WATER
STARTER MOTOR
HEAT EX− AND SOLENOID BATTERY NEG (−) RELAY K9 LOCATION BATTERY POS (+)
CHANGER B1 M10 (ISOLATED GROUND) M8
FIGURE 14. TYPICAL GENSET CONFIGURATION

SEQUENCE OF OPERATION Start Disconnect: As the genset runs up to rated
speed and voltage and the output signal from the
Refer to Figure 25 while working through the follow-
AVR crosses a threshold of approximately 70 VDC,
ing sequences of operation.
start disconnect relay K4 opens contacts 9-10 and
Start Sequence closes contacts 1-2 and 3-4.
Prime/Preheat: Holding switch S1 in its Stop/Pre- • Closing contacts 1-2 keeps run relay K3 ener-
heat position energizes relays K5 (glow plugs) and gized and the genset running when control
K11 (fuel prime). switch S1 is released. The genset will not con-
• When relay K5 contacts 87-30 close, glow tinue to run if the generator fails to develop the
plugs HR1-HR3(4) are energized to preheat threshold voltage necessary to energize
the engine combustion chambers. relay K4.
• When relay K11 contacts 30-87 close, fuel lift • Opening contacts 9-10 deenergizes starter
pump E5 is energized to lift fuel to the fuel injec- relay K1 and glow plug relay K5, stopping
tion pump. cranking and preheating. This will occur even
before control switch S1 is released.
Start: Holding switch S1 in its Start position ener-
gizes start relay K2. Start relay K2 contacts 87-30 • Closing contacts 3-4 arms the fault shutdown
close to energize run relay K3. Relay K3 closes circuits. See Fault Shutdown Sequence.
contacts 30-87 to energize: Run: The genset runs up to rated speed and volt-
• Meter M1, and meters M2-M4 when provided. age in a few seconds. As the load varies, the AVR
maintains rated voltage by varying generator field
• Low coolant level switch S3 and relay K6, when
strength (see Automatic Voltage Regulator) and the
provided.
internal mechanical governor maintains nominal
• Field windings of battery charging alterna- frequency by moving the fuel rack.
tor G1.
Fault Shutdown Sequence
• Fuel pump E5.
“Check Engine” Faults: The following fault
• AVR start disconnect and over-speed fault cir- switches shut down the genset by grounding termi-
cuits. nal 2 on fault breaker CB2, causing it to trip:
• Fueling relay K8. Relay K8 closes contacts • High engine temperature switch S2
87-30 to energize fuel stop solenoid K7, which
pulls in to move the fuel rack to its maximum • Low coolant level switch S3, via relay K6
fuel position and open its internal “AUX” con- • Low oil pressure switch S4
tacts. When the contacts open, starter relay K1
and relay K10 are energized. (Opening the • High exhaust temperature switch S5
contacts removes B+ from the ground side of • AVR overspeed circuit
the relay K1 and K10 coils, which are grounded
through pull-in coil P.) “Check Generator” Faults: Fault breaker CB5
trips if generator quadrature winding current is too
• When relay K1 contacts 87-30 close, start- high.
er motor B1 is energized via its solenoid to
crank the engine. Stop Sequence
• When relay K10 contacts 30-87 close, One touch of switch S1 to its Stop position connects
glow plug relay K5, fuel prime relay K11 B+ to the ground side of run relay K3, deenergizing
and isolated ground relay K9 will continue it and stopping the genset by deenergizing fuel stop
to be energized during cranking. solenoid K7, shutting off fuel.

Automatic Voltage Regulator
The automatic voltage regulator (AVR) is mounted
as shown in Figure 15 on the floor of the control box
and is connected as shown in Figure 16.
WARNING HAZARDOUS VOLTAGE Touching
uninsulated live parts inside the control box can
result in severe personal injury or death. For
your protection, stand on a dry wooden plat-
form or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry and
use tools with insulated handles.
ADJUSTING VOLTAGE
The AVR has a voltage adjustment pot and
50/60 Hz selector switch. Do not readjust the
sealed V/HZ break point pot. To adjust voltage:
1. Disconnect all generator loads.
2. Check the position of the 50/60 Hz selector
switch and change it if necessary.
3. Start the genset and turn the voltage adjusting
pot to obtain rated output voltage.
4. Check and readjust frequency (p. 37 or 38). TERMINAL K4-5
Ground to keep genset
5. Readjust voltage if frequency was changed. running while testing
generator
FLASHING THE FIELD
Disconnect P1/J1 inside the control box and con-
nect the test adapter and 6 volt dry cell battery (Fig-
ure 16) for a few seconds: B+ to F1 (P1-8) and B- FIGURE 15. VOLTAGE REGULATOR (AVR)
to F2 (P1-1). Reconnect P1/J1. See Troubleshoot-
ing if flashing the field does not restore voltage.
TESTING AVR vs GENERATOR
To find out whether the AVR or the generator is
faulty:
1. Disconnect all generator loads.
2. Disconnect P1/J1 inside the control box and
connect the test adapter and 6 volt dry cell bat-
tery (Figure 16).
3. Start the genset and close terminal K4-5 (Fig-
ure 15) to ground to disengage the starter and
keep the genset running.
4. Measure voltage across the test terminals. If
the AVR connections are good and generator
output is 100-140 VAC across Q1-S2 and
130-150 VAC across Q1-Q2, replace the
AVR. See Troubleshooting (p. 48) if there is no
voltage.

AVR CONNECTIONS
EXCITER
F1
F2
G21
Q2
Q1
S2
T1 T2 T3 T4 T5 T6 T7 T8 T9 T10 T11 T12
SEE RECONNECTION DIAGRAMS—FIG. 27
REAR VIEW OF P2
4 1 5 6 7 8
VR21 (AVR) P2 P1
3 2 4 3 2 1
REAR VIEW OF P1
612-6673
K4−5(START−DISC)
CB2−2(OVERSPEED)
B+
SUGGESTED CONSTRUCTION OF ADAPTER FOR GENERATOR/AVR TESTING AND FIELD FLASHING
100-140V AC
130-150V AC
RED BLACK
+ -
6 VOLT
DRY CELL
BATTERY F2 F1 Q2 Q1 S2
VIEW B-B
Connect Terminal F2 to PIN 8, F1 to PIN 1, Q2 to PIN 5, Q1 to PIN3 and S2 to PIN4
Use DEUTSCH connector jack 0T04-08P (ONAN PN 324-1542 jack, 324-1491 pins and 323-1544 wedge) to
mate connector P1. Use 18 AWG leads.
FIGURE 16. AVR CONNECTIONS AND ADAPTER FOR GENERATOR/AVR TESTING AND FIELD FLASHING

Generator
These are 4-pole, rotating-field, brushless, single- movement and vibration. For connections, use the
bearing, electronically regulated generators (Fig- terminals on the terminal blocks and line circuit
ure 17). See BASICS at the end of this section for a breakers in the output box. Make sure the generator
description of generator operation. is connected for the required voltage output (Fig-
ure 27) and that properly sized line circuit breakers
VOLTAGE REGULATION have been installed.
See Automatic Voltage Regulator.
WARNING HAZARDOUS VOLTAGE Touching
CONNECTIONS uninsulated live parts inside the output box can
Wiring connections should be made by a licensed result in severe personal injury or death. For
electrician and be inspected and approved before your protection, stand on a dry wooden plat-
operation. All wiring methods, connections, wire form or rubber insulating mat, make sure your
ampacities, equipment grounding, materials, etc. clothing and shoes are dry, remove jewelry from
must comply with the applicable codes. your hands and use tools with insulated han-
dles.
WARNING Improper wiring can cause fire or
electrocution resulting in severe personal inju- WARNING Accidental starting can cause se-
ry or death and property damage. vere personal injury or death. Disconnect the
Use flexible conduit and stranded conductors to negative (-) cable(s) at the battery(ies) to pre-
make connections at the generator to take up vent the engine from starting.
THROUGH BOLT (4) EXCITER STATOR, QUADRATURE, FIELD, MAIN STATOR

TORQUE DRY TO STATOR & VOLTAGE SENSING LEADS
38-43 N-M
(28-32 FT-LB)
DRIVE DISC BOLT (6)

TORQUE DRY TO
END
27-31 N-M (20-23 FT-
COVER
LB)
SMOOTH, ROUNDED
SIDES OF WASHERS
TOWARD DISC
END BELL
ASSEMBLY
DISC HUB BOLT(6)
TORQUE DRY TO
50-57 N-M (37-42 FT-
LB) SMOOTH,
ROUNDED SIDES OF
ROTOR WASHERS TOWARD
BEARING DISC
EXCITER ROTOR MAIN ROTOR
FIGURE 17. GENERATOR ASSEMBLY

TESTING set has been in standby for a long time in high hu-
midity conditions and repeat the test.
Testing Winding Insulation Resistance
Testing Winding Resistance
A 500 VAC megger is recommended for the winding
insulation resistance tests prescribed below. A test Use a digital ohmmeter or Wheatstone bridge to
consists of applying the test potential between the measure winding resistance. The device should
winding and ground (winding laminations) for a peri- have a precision of at least 0.01 ohm.
od of 10 minutes and recording resistance at 1 min- Exciter Stator
ute and again at 10 minutes.
Winding Insulation Resistance: Disconnect AVR
Resistance values of at least 5 megohms should be connector P1/J1 inside the control box. Using the
obtained for a new generator with dry windings. The test adapter (p. 29), connect pin P1-1 or P1-8 to the
polarization index should also be at least 2 (the ratio megger and conduct the test as instructed under
of the resistance reading at ten minutes to the read- Testing Winding Insulation Resistance.
ing at one minute). For a set that has been in ser-
Winding Resistance: Using the test adapter
vice, the resistance reading should not be less than
(p. 29), measure winding resistance between pins
1 megohm nor the polarization index less than 2.
P1-1 and P1-8. Replace the exciter stator if the re-
Dry the windings if low readings are obtained or the sistance is not as specified in Table 4.
END BELL CASTING EXCITER STATOR LEADS

ORIENT SO THAT FIELD COIL F1 (PIN P1-8) & F2 (PIN P1-1)
WHERE LEADS ATTACHED IS UP
STATOR MOUNTING SCREWS BEARING

8 LB-FT (11 N-M) TORQUE BORE O-RING
FIGURE 18. EXCITER STATOR AND END BELL

Exciter Rotor Each assembly has a field terminal (F1+ or F2- ) for
connecting the leads from the main rotor (generator
Winding Insulation Resistance: Disconnect all
field).
six exciter rotor leads from diode terminals CR1
through CR6 and isolate them from ground. Con- Diode Resistance: Measure electrical resistance
nect any lead to the megger and conduct the test as between diode terminals CR1, CR2 and CR3 and
instructed under Testing Winding Insulation Resist- field terminal F1+ on the positive diode assembly
ance. and between diode terminals CR4, CR5 and CR6
Winding Resistance: Measure electrical resist- and field terminal F2- on the negative diode assem-
ance across each pair of rotor windings: T11-T12, bly. Reverse the meter test probes and repeat the
T21-T22, T12-T13, T22-T23, T13-T11 and tests. The electrical resistance across each diode
T23-T21. See the connection schematic. Replace should be high in one direction and low in the other.
the exciter rotor if the resistance of any winding is If the resistance is high or low in both directions, re-
not as specified in Table 4. place the whole diode assembly.
Rotating Rectifiers Replacing Diode Assembly: Make sure the re-
The rotating rectifier assembly is mounted on the placement diode assembly is of the correct polarity,
back face of the exciter rotor. It consists of one posi- positive (+) or negative (- ). Then disconnect all
tive (+) and one negative (- ) diode assembly. Each leads from the defective diode assembly and re-
assembly carries three diodes in an epoxy potting. move the two mounting screws. Mount the new
Each diode has a terminal for connecting the ap- diode assembly, reconnect all leads and torque the
propriate lead from the exciter rotor (CR1-CR6). terminal screws to 24 lb-in (2.6 N-m).
DIODE TERMINAL (6) FOR EXCITER WINDING POSITIVE (+) NEGATIVE (-)
LEAD. TORQUE TO 24 LB-IN (2.6 N-M). USE FLAT DIODE ASSEMBLY DIODE ASSEMBLY
WASHER TO PROTECT LEAD CONNECTOR LEFT-HAND SIDE, RIGHT-HAND SIDE,
SHAFT KEY UP SHAFT KEY UP
DIODE ASSEMBLY
MOUNTING SCREW (2)
TERMINALS F1+ AND F2- FOR

MAIN ROTOR LEADS
CONNECTION SCHEMATIC TORQUE TO 24 LB-IN (2.6 N-M)
FIGURE 19. ROTATING RECTIFIER ASSEMBLY

Main Rotor Connect either or both leads to the megger and con-
duct the test as instructed under Testing Winding In-
Winding Insulation Resistance: Disconnect the
sulation Resistance.
main rotor leads from terminals F1+ and F2+ on the
rotating rectifier assemblies and isolate them from Winding Resistance: Disconnect the main rotor
ground. Tag and mark each lead with its terminal leads from terminals F1+ and F2+ on the rotating
number (F1+ or F2+). rectifier assemblies and measure electrical resist-
CAUTION Because of the opposing residual
ance between them. Replace the rotor if the resist-
ance is not as specified in Table 4.
magnetism of the rotor, it might be difficult to re-
establish self excitation if the polarity of the Reconnect the rotor leads and torque the terminals
main rotor leads is reversed upon reassembly. to 24 lb-in (2.7 N-m) when reassembling.
DRIVE DISC MAIN MAIN ROTOR LEADS PASS THROUGH EX-

CHAMFERED EDGE FIELD CITER ROTOR TO F1+ AND F2- ON RO-
TOWARDS FLYWHEEL TATING RECTIFIERS. DISCONNECT
LEADS WHEN TESTING MAIN ROTOR.
TORQUE NUTS TO 24 LB-IN (2.6 N-M)
EXCITER ROTOR ROTOR BEARING

FAN PRESS ON TO SHOULDER PRESS ON TO SHOULDER
BLADES DO NOT LUBRICATE SHAFT DO NOT LUBRICATE SHAFT
FIGURE 20. ROTOR ASSEMBLY

Main Stator from its grounded neutral connection and isolate it.
Leave the other windings grounded. Connect either
Quadrature Winding Insulation Resistance: Dis- or both winding leads to the megger and conduct
connect AVR connector P1/J1 inside the control the test as instructed under Testing Winding Insula-
box. Using the test adapter (p. 29), connect pin tion Resistance.
P1-4 or P1-5 to the megger and conduct the test as
instructed under Testing Winding Insulation Resist- Main Winding Resistance: Disconnect all main
ance. stator leads from the terminals to which they are
connected and measure resistance across the fol-
Quadrature Winding Resistance: Using the test lowing lead pairs:
adapter (p. 29), measure winding resistance be-
tween pins P1-4 and P1-5 with a Wheatstone • 4-Lead Generators—T1-T2 and T3-T4 .
bridge. Replace the stator assembly if the resist- • 12-Lead Generators—T1-T4 , T2-T5 , T3-T6 ,
ance is not as specified in Table 4. T7-T10 , T8-T1 1, T9-T12 .
Main Winding Insulation Resistance: Test each Replace the stator assembly if the resistance of any
winding separately. Disconnect the winding lead winding is not as specified in Table 4.
TABLE 4. GENERATOR STATOR AND ROTOR WINDING RESISTANCES

REFERENCE MAIN QUADRATURE MAIN ROTOR EXCITER ROTOR EXCITER STATOR
LENGTH WINDING WINDING WINDING RE- WINDING RE- WINDING RE-
MILLIMETERS RESISTANCE RESISTANCE SISTANCE SISTANCE SISTANCE
(INCHES)1 OHMS2, 3 OHMS2 OHMS2 OHMS2 OHMS2
4-Lead Generators (Single-Phase)
341 (13.4) 0.17-0.22 1.33-1.63 2.60-3.20 0.58-0.71 13-16
378 (14.9) 0.09-0.12 0.79-0.97 2.17-2.65 0.58-0.71 13-16
12-Lead Generators (Three-Phase)
341 (13.4) 0.36-0.44 2.32-2.83 2.60-3.20 0.58-0.71 13-16
378 (14.9) 0.15-0.19 1.83-2.23 2.17-2.65 0.58-0.71 13-16
REFERENCE LENGTH
1. Measure this length to identify the generator. The corresponding rotor stack lengths are slightly greater.
2. If high, recheck winding resistance after the windings have cooled to room temperature.
3. The main windings are probably good if some of the resistances fall outside the range but are all within 10 percent of each other.

DISASSEMBLY REASSEMBLY
The generator is heavy. You will need an assistant Reassembly is the reverse of disassembly. Note the
and hoist of sufficient capacity. following when reassembling the generator:
WARNING Accidentally dropping the genera-
tor can damage it and cause severe personal in- 1. Press a new exciter rotor or rotor shaft bearing
jury or death. Use a hoist and straps of suffi- on up to its locating shoulder on the shaft. Do
cient capacity and attach them so that the load not lubricate the shaft (Figure 20).
cannot shift.
2. Torque the six disc-to-hub bolts (Figure 17) to
Disconnect the negative (- ) cable(s) at the bat- 50-57 N-m (37-42 lb-ft). Make sure that:
tery(ies) to prevent the genset from starting.
A. The chamfered edge on the drive disc
WARNING Accidental starting can cause se- perimeter faces out to make assembly
vere personal injury or death. Disconnect the with the flywheel easier.
vent the genset from starting. B. The rounded edges of the washers are
1. Disconnect all power output and remote control on the disc side.
connections and conduit at the generator. For
3. Torque the six disc-to-flywheel bolts (Fig-
easier reconnections later, make sure each
ure 17) to 27-31 N-m (20-23 lb-ft). Make sure
lead is clearly marked.
the rounded edges of the washers are on the
2. Disconnect engine harness connector P5/J5, disc side.
AVR connectors P1/J1 and P2/J2, the connec-
tor P1 lead secured to the grounding stud in- 4. Use the four throughbolts to help guide the sta-
side the control box and the control box tor on. Thread the ends with less thread into the
grounding strap secured to the generator. Re- flywheel housing and make sure the threads
move the control box, output box and saddle as bottom.
an assembly.
5. Make sure the scribed stator-flywheel index
3. Hook the genset lifting eye with a hoist, remove lines (Step 5, Disassembly) register.
the throughbolts in the two generator mounts,
tip the generator end up slightly with the hoist 6. Torque the two exciter stator screws (Fig-
and block the flywheel housing to support the ure 18) to 11 N-m (8 lb-ft). The pole to which
engine while the generator is being serviced. the leads are tied must be up.
4. Cinch a strap around the middle of the genera-
tor stator and take up slack with the hoist. 7. Wipe the bearing bore in the end bell lightly with
molybdenum disulfide grease and make sure
5. Scribe lines before separating the end bell from the rubber O-ring (Figure 18) is in place.
the stator and the stator from the flywheel
housing to register the parts for reassembly. 8. Assemble the end bell to the stator, making
sure the scribed index lines (Step 5, Disassem-
6. Remove the four nuts on the throughbolts and
tap the end bell free of the stator. bly) register and the rotor bearing seats fully in
the bore. Pull the field leads out the same open-
7. Tap the stator free of the flywheel housing, ing as the stator leads. Torque the nuts on the
carefully draw the stator straight back until it generator throughbolts to 38-43 N-m
clears the ends of the throughbolts and remove (28-32 lb-ft).
the throughbolts.
9. Secure the end bell cover plate and torque the
8. Cinch a strap around the rotor and remove the
four screws to 3.8 N-m (8 lb-in).
six disc-to-flywheel bolts (Figure 17). When re-
moved, cradle the rotor horizontally in wooden 10. Reassemble all the remaining components.
blocks to prevent damage to windings, lamina- Make sure to resecure the ring terminals of
tions and drive disc. grounding straps and leads with two star wash-
9. Use a gear puller to remove the rotor bearing ers, one on each side, for good electrical conti-
or exciter rotor (Figure 20). nuity.

BASICS wave rectifier bridge which converts exciter
output (3-phase AC) to DC. The rectifier bridge
Refer to Figure 21 while working through the follow- (rotating rectifiers) is mounted on the rotor.
ing explanation.
4. Exciter rotor output is proportional to exciter
1. The generator field (main rotor) is rotated by field (stator) strength, which, in turn, is propor-
the engine to induce output current (AC) in the tional to exciter field current.
main stator windings.
5. The AVR regulates exciter field current by
2. Generator output is proportional to field comparing generator output voltage and fre-
strength, which is varied to match the load. quency with reference values. Power for excit-
Nominal output voltage and frequency are er field current is supplied by quadrature wind-
maintained by the AVR and engine governor, ings in the main stator assembly.
respectively.
6. Residual field magnetism and a permanent
3. Field strength is proportional to field current, magnet in one of the exciter stator poles initi-
which is supplied by the exciter through a full- ates “self-excitation” during startups.
VOLTAGE SENSING AC POWER OUTPUT

VOLTAGE (S2) (T1-T12)
REGULATOR
(AVR) EXCITER POWER
(Q1-Q2)
EXCITER FIELD
CURRENT (F1-F2)
EXCITER MAIN STATOR

FIELD
RECTIFIERS
ROTATING
MAIN FIELD ROTATING

EXCITER CURRENT MECHANICAL
MAIN ROTOR
ROTOR POWER
INPUT
FIGURE 21. GENERATOR BASICS

Adjusting the Fuel Stop and Frequency
FUEL STOP (EXCEPT MDKAL SPEC A)
FUEL STOP ADJUSTABLE SPRING
1. Make sure the fuel stop solenoid is secure. SOLENOID LINK CLIP
2. If the seal on the lever stop screw is broken:
A. Back out the stop screw so that it does
not touch the governor stop lever when
turned clockwise as far as it will go.
B. Turn the screw back in one half turn past
the point where it just touches the lever.
C. Set the locknut and seal the adjustment.
3. Push the solenoid in until it seats, rotate the
stop lever towards the solenoid and adjust the
length of the link so that its end lines up with the
LEVER STOP GOVERNOR
hole in the lever. Then increase the length one SCREW STOP LEVER
turn (counterclockwise) to make sure the sole-
noid will seat and open its AUX contacts when
energized. FIGURE 22. FUEL STOP ADJUSTMENT
(EXCEPT MDKAL SPEC A)
4. Set the locknut and secure the link and lever
with the spring clip.
FREQUENCY (EXCEPT MDKAL SPEC A)
50 Hz Frequency Adjustment
1. Make sure the AVR frequency selector switch
(p. 28) is set at 50 Hz.
2. Back off screw A (Figure 23) to free the front B
(60 Hz) lever and prevent overspeed shut-
down, snug screw D and set the locknuts. C
3. Disconnect all loads and start the genset.
4. Back off screw C, turn screw B to obtain a no- D
load frequency of 52.5 Hz, snug screw C and
set the locknuts. There is no droop adjustment. A
5. Readjust frequency and voltage (p. 28) as nec-
essary.
FIGURE 23. FREQUENCY ADJUSTMENT
60 Hz Frequency Adjustment (EXCEPT MDKAL SPEC A)
1. First adjust genset frequency to 50 Hz if the ad-
justment seal on screw B (Figure 23) is broken.
Snug screw C if necessary.
2. Stop the genset, reset the AVR frequency se-
lector switch (p. 28) to 60 Hz and restart.
3. Back off screw D, turn screw A to obtain a no-
load frequency of 63 Hz, snug screw D and set
the locknuts. There is no droop adjustment.
essary.

FUEL STOP (MDKAL SPEC A)
1. Make sure the fuel stop solenoid is securely
mounted. ADJUSTABLE SPEED STOP SPRING
LINK SCREW CLIP
2. If the seal on the lever stop screw is broken:
A. Back out the stop screw so that it does
not touch the governor stop lever when
turned clockwise as far as it will go.
B. Turn the screw back in one half turn past
the point where it just touches the lever.
C. Set the locknut and seal the adjustment.
3. Push the solenoid in until it seats, rotate the
stop lever towards the solenoid and adjust the
length of the link so that its end lines up with the FUEL STOP
hole in the lever. Then increase the length one SOLENOID
turn (counterclockwise) to make sure the sole-
noid will seat and open its AUX contacts when
energized. SPEED LEVER STOP GOVERNOR
4. Set the locknut and secure the link and lever SCREW SCREW STOP LEVER
with the spring clip.
FREQUENCY (MDKAL SPEC A) FIGURE 24. FUEL STOP AND FREQUENCY AD-
JUSTMENTS (MDKAL SPEC A)
1. Check the position of the AVR frequency selec-
tor switch (p. 28) and set as required for 50 Hz
or 60 Hz.
2. Make sure that the internal governor spring is
right for 50 Hz or 60 Hz. Change the spring if
necessary in accordance with the Engine
Workshop Manual.
3. Disconnect all loads from the generator and
start the genset.
4. Back out the speed stop screw (Figure 24) and
turn the speed screw to obtain the required no-
load frequency of 52.5 Hz or 63 Hz. Snug the
speed stop screw and locknuts. There is no
droop adjustment.
essary.

Troubleshooting
Fault Circuits ings were noted before shutdown; that is, whether
shutdown was due to low oil pressure or to high en-
“Check Generator” Fault: If the “Check Genera-
gine temperature. Shutdown occurs when oil pres-
tor” fault breaker trips, as indicated by the extended
sure falls below 14 psi (97 kPa) or engine tempera-
reset button, the genset may have been over-
loaded. Push the reset button. ture reaches 222° F (106° C).
“Check Engine” Fault: The “Check Engine” faults Troubleshooting Tables

are: low engine oil pressure, high coolant tempera-
ture, low coolant level (optional), high exhaust tem- The following troubleshooting tables are designed
perature, over/underspeed and over/undervoltage. to help you think through genset problems. The
The “Check Engine” fault breaker will trip, as indi- problem could be as simple as an empty fuel tank,
cated by the extended reset button. Push the reset closed fuel shutoff valve or tripped circuit breaker.
button.
CAUTION A replacement AVR can be damaged
Engine Gauges
if troubleshooting does not uncover generator
Time can be saved if abnormal engine gauge read- repairs that may be required.
ENGINE DOES NOT STOP RUNNING
WARNING There are hazards present in troubleshooting that can cause equipment damage, se-
vere personal injury or death. Troubleshooting must be performed by qualified persons who
know about the hazards of fuel, electricity and machinery. Read Safety Precautions and observe
all instructions and precautions in this manual.
Possible Cause Corrective Action
1. Faulty stop solenoid or governor a. Push the governor stop lever to the right and hold it there until
the engine stops (see figure).
b. Make sure that the fuel stop solenoid is mounted securely.
c. Disconnect the linkage at the governor stop lever and check
for internal binding in the fuel stop solenoid. Replace the so-
lenoid if the armature binds or the internal spring does not
positively and smoothly push the armature out to its fully ex-
tended position.
d. Readjust the fuel stop link (p. 37 or 38).
e. Repair the internal governor mechanism according to the
Engine Workshop Manual.
STOP

ENGINE DOES NOT CRANK FROM REMOTE PANEL
1. Tripped DC Circuit Breaker CB1 a. Push ON to reset (p. 25).

b. If the breaker trips again, reconnect the glow plug lead if
loose and touching ground (p. 24).
2. OFF or tripped Emergency Stop a. Push ON to reset (p. 25).

Breaker CB4 b. If the breaker trips again, open the control box (p. 25) and re-
connect any loose wiring that may be touching ground.
3. “Check Engine” fault See “CHECK ENGINE” FAULT SHUTDOWN.
4. Fault in remote circuit If the genset starts at the genset panel, repair the remote cir-
cuit as necessary.
ENGINE DOES NOT CRANK FROM GENSET PANEL
1. Tripped DC Circuit Breaker CB1 a. Push ON to reset (p. 25).

b. If the breaker trips again, reconnect the glow plug lead if
loose and touching ground (p. 24).
2. OFF or tripped Emergency Stop a. Push ON to reset (p. 25).

Breaker CB4 b. If the breaker trips again, open the control box (p. 25) and re-
connect any loose wiring that may be touching ground.
3. “Check Engine” fault See “CHECK ENGINE” FAULT SHUTDOWN.

ENGINE DOES NOT CRANK FROM GENSET PANEL (CONT.)
4. Low cranking voltage a. Clean and tighten or replace the positive (+) and negative (- )
battery cable connectors and cables.
b. Recharge or replace the battery. Specific gravity for a fully
charged battery is approximately 1.260 at 80° F (27° C).
c. Readjust or replace the V-belt if loose or worn (p. 20).
d. Repair or replace the battery charging alternator (G1) if nor-
mal battery charging voltage is not 12.5-15 volts for a 12 volt
battery system or 24-27 volts for a 24 volt battery system.
5. Disconnected engine harness Reconnect J5/P5.

connector J5/P5
6. Faulty starter motor/solenoid Check for B+ at terminal SW on the starter solenoid while
holding control switch S1 at Start:
• B+ present: Repair or replace the starter/solenoid.
• B+ absent: Go to Step 7.
7. Faulty stop solenoid or link ad- Hold control switch S1 at Start and check for solenoid action.
justment (AUX contacts must If none, disconnect the red lead (solenoid + POS terminal)
open to energize relay K1) or and check for B+ at the end of the lead:
governor • B+ absent: Go to Step 8.
• B+ present: Reconnect the red lead, disconnect the link
and hold S1 at Start:
• Solenoid pulls in and engine cranks:
• Readjust the fuel stop link (p. 37 or 38).
• Check for internal binding of the governor
mechanism and repair as necessary according
to the Engine Shop Manual.
• Solenoid pulls in but engine does not crank:
Disconnect the white wire (AUX) and replace the
solenoid if there is B+ at the AUX terminal.
• Solenoid does not pull in: Replace the solenoid.

ENGINE DOES NOT CRANK FROM GENSET PANEL (CONT.)
8. Faulty start/run control circuit a. Open the control box (p. 25) and check for B+ at:
• The load terminal on CB1
• Terminal 2 on CB4
• Terminal 3 on CB2
• Terminal 2 on switch S1.
Repair or reconnect wiring and components as necessary.
b. Disconnect the leads from control switch S1. Replace switch
S1 if contacts 2-3 are open when the switch is held at Start.
c. Disconnect the leads from terminals 9 and 10 on start discon-
nect relay K4. Replace relay K4 if 9-10 (NC) is open.
d. Remove starter relay K1 from its socket. Apply battery volt-
age across coil terminals 85-86. Replace relay K1 if contacts
87-30 (NO) do not close.
e. Remove start relay K2 from its socket. Apply battery voltage
across coil terminals 85-86. Replace relay K2 if contacts
f. Remove run relay K3 from its socket. Apply battery voltage
across coil terminals 85-86. Replace relay K3 if contacts
g. Remove fueling relay K8 from its socket. Apply battery volt-
age across coil terminals 85-86. Replace relay K8 if contacts
h. If the relays and switch are good, reconnect or repair wiring
as necessary.

ENGINE CRANKS BUT DOES NOT START
1. Blocked or restricted fuel supply a. Open any closed shutoff valve.

b. Check fuel level and refill as necessary.
c. Prime the fuel system (p. 24).
d. Check for fuel (air) leaks at all fittings and tighten as neces-
sary.
e. Replace the fuel filter (p. 23) and any other filter in the fuel
supply system.
f. Disconnect the two leads to the fuel pump (p. 26) and check
for B+ at the red lead while cranking and for ground continuity
at the black lead.
• If there is no B+ at the red lead, check for and reconnect
or repair wiring between run relay K3 terminal 87 and
engine harness connector pin J5-3.
• Repair or replace the black lead if there is no ground
continuity.
• If there is B+ and ground continuity, go to Step g.
g. Check for fuel pump operation by priming with the low pres-
sure bleed open (p. 24). Replace the fuel pump (p. 26) if it
does not pump.
h. Check fuel pump (p. 26) static pressure by connecting a
0-15 psi (0-100 kPa) gauge at the outlet. Replace the pump
if fuel pressure does not stabilize at 3.5-6 psi (24-41 kPa).
2. Blocked air inlet Service as necessary.
3. Low engine temperature a. Plug in, repair or install heaters for the engine coolant and oil.
b. Replace the engine oil if it is not of the recommended viscos-
ity for the ambient temperature.

ENGINE CRANKS BUT DOES NOT START (CONT.)
4. Low cranking voltage a. Clean and tighten or replace the positive (+) and negative (- )
battery cable connectors and cables.
b. Recharge or replace the battery. Specific gravity for a fully
charged battery is approximately 1.260 at 80° F (27° C).
c. Readjust or replace the V-belt if loose or worn (p. 20).
d. Repair or replace the battery charging alternator (G1) if nor-
mal battery charging voltage is not 12.5-15 volts for a 12 volt
battery system or 24-27 volts for a 24 volt battery system.
5. Faulty glow plugs a. Reconnect the glow plug lead (p. 24) if loose.
b. Check for B+ at the glow plug bus bar while cranking.
• B+ absent:
• Open the control box (p. 25) and remove relay K10
from its socket. Apply battery voltage across coil
terminals 85-86. Replace relay K10 if contacts
• Remove relay K5 from its socket. Apply battery volt-
age across coil terminals 85-86. Replace relay K5
if contacts 87-30 (NO) do not close.
• If the relays are good, reconnect or repair wiring as
necessary.
• B+ present: Remove the glow plug bus bar and check
for ground continuity across each glow plug. Replace all
three (four) glow plugs if any glow plug is open.
Note: If a glow plug does not come out after un-
screwing it, or the end has broken off, it will be nec-
essary to remove the engine head to remove the
glow plug and/or debris from the cylinder. (Glow
plugs can swell if preheat voltage is greater than 14
volts, such as when a battery booster is used for
starting.)

ENGINE STARTS BUT DOES NOT RUN
1. “Check Generator” fault a. Reset “Check Generator” fault breaker CB5 (p. 25).
b. Run with fewer loads, especially when low power factor
loads are connected or large motor loads are cycling on and
off.
2. Faulty start disconnect circuit a. Open the control box (p. 25) and check for B+ at terminal 6
on start disconnect relay K4. Reconnect wiring as necessary.
b. If loose, reconnect wiring at terminals 1 and 2 on start discon-
nect relay K4 and terminals 1 and 2 on “Check Generator”
fault breaker CB5.
c. Ground terminal 5 on start disconnect relay K4 (p. 28) when
the engine starts up:
• Engine stops: Replace relay K4.
• Engine runs: Check generator output voltage:
• Normal output: Disconnect AVR connector P2/J2.
Check for ground continuity at pin P2-4 and conti-
nuity between pin P2-1 and K4-5. Reconnect or re-
pair wiring as necessary. If that does not help, re-
place the AVR.
• No output:
• Check electrical continuity across fault breaker
CB5 and replace if necessary.
• Flash the field (p. 28).
• If there is still no output voltage, conduct the
AVR/GENERATOR TEST (p. 28). Based on
the results, replace the AVR or go to FAULTY
GENERATOR.

“CHECK ENGINE” FAULT SHUTDOWN
1. High exhaust temperature a. Open the sea cock.

(check whether exhaust hose b. Remove blockage in the sea water strainer.
feels hotter than usual)
c. Prime the sea water pump (p. 22).
d. Replace the sea water pump impeller (p. 22).
e. Clean the heat exchanger (p. 22).
f. Remove blockage covering the sea water hull strainer.
2. Low engine oil pressure a. Check oil level, repair leaks and fill to proper level (p. 17).
b. Service the engine lubrication system in accordance with the
Engine Workshop Manual.
c. Replace switch S4 if it closes above 14 psi (97 kPa).
3. High engine temperature or low a. Check coolant level, repair leaks and fill to proper level
coolant level (p. 18).
b. Check V-belt tension and adjust as necessary (p. 20).
c. Clean and service the cooling system as required to restore
full cooling capacity (p. 18).
d. Replace switch S2 if it closes below 222° F (106° C).
4. Improper AVR selector position Check whether the 50/60 Hz selector switch (p. 28) is at
(60 Hz gensets) 50 Hz and set it to 60 Hz. Readjust frequency (p. 37 or 38).
(Overspeed cutout when the AVR is set at 50 Hz is approxi-
mately 64 Hz.)
5. Over/Underspeed a. Readjust frequency (p. 37 or 38).

b. Check for internal binding of the governor mechanism and
repair as necessary according to the Engine Shop Manual.
c. Run with fewer loads, especially when low power factor
loads are connected or large motor loads are cycling on and
off.

ENGINE UNSTABLE OR LACKS POWER
1. Air leaks or fuel restriction a. Check for fuel (air) leaks at all fittings and tighten as neces-
sary.
b. Replace the fuel filter (p. 23) and any other filter in the fuel
supply system.
c. Check fuel pump (p. 26) static pressure by connecting a
0-15 psi (0-100 kPa) gauge at the outlet. Replace the pump
if fuel pressure does not stabilize at 3.5-6 psi (24-41 kPa).
2. Improper 50/60 Hz selector Set the 50/60 Hz selector switch in the proper position for the
switch position on AVR application (p. 28).
3. Misadjusted frequency or fuel a. Readjust frequency (p. 37 or 38).

stop linkage or faulty governor b. Readjust the fuel stop link (p. 37 or 38).
c. Check for internal binding of the governor mechanism and
repair as necessary in accordance with the Engine Shop
Manual.
4. Air trapped in water separator a. Reconnect the fuel lines to any alternative fittings on the wa-
ter separator.
b. Install a different model of water separator.
c. Relocate the genset fuel pickup tube to reduce pickup of aer-
ated fuel returned from the propulsion engines.
5. Contaminated fuel Connect the engine to a container of known fuel quality. Re-
place the fuel in the supply tank if performance improves.
6. Worn engine or fuel injection sys- Service in accordance with the Engine Workshop Manual.
tem or improper injection timing

NO OUTPUT VOLTAGE
1. Line circuit breakers OFF Find out why the breaker was turned OFF, make sure it is
safe to reconnect power and then throw ON the breaker.
2. Line circuit breakers tripped Clear the short circuit or ground fault that caused tripping and
then RESET the breaker.
3. Line circuit breakers faulty Shut down the genset, disconnect all other sources of power,
RESET the breaker and then check for electrical continuity
across each pole. Replace a breaker if there is measurable
resistance across any pole.
FAULTY GENERATOR (PAGE 28)
1. Open exciter field windings Check and replace as necessary (p. 31)
2. Open exciter rotor windings Check and replace as necessary (p. 32)
3. Faulty rotating rectifier assembly Check and replace as necessary (p. 32)
4. Open main rotor windings Check and replace as necessary (p. 33)
5. Open stator windings (main or Check and replace as necessary (p. 34)
quadrature)

OUTPUT VOLTAGE TOO HIGH OR TOO LOW
1. Improper voltage adjustment Readjust voltage (p. 28).
2. Improper frequency adjustment Readjust frequency (p. 37 or 38).
3. Improper generator connections Reconnect according to Figure 27 (p. 53).
4. Faulty rotating rectifier assembly Check and replace as necessary (p. 32).
5. Shorted quadrature winding Check and replace as necessary (p. 34).
6. Faulty voltage regulator Replace the voltage regulator (p. 28).
UNSTABLE OUTPUT VOLTAGE
1. Improper AVR selector position Check whether the 50/60 Hz selector switch (p. 28) is at
(50 Hz gensets) 60 Hz and set it to 50 Hz. Readjust frequency (p. 37 or 38).
(Because frequency is below 60 Hz, the AVR will attempt to
“unload” the engine by reducing voltage.)
2. Improper frequency adjustment Readjust frequency (p. 37 or 38).
3. Improper voltage adjustment Readjust output voltage (p. 28).
4. Unstable engine speed See ENGINE UNSTABLE OR LACKS POWER.

UNSTABLE OUTPUT VOLTAGE (CONT.)
5. Unevenly distributed loads Measure output current in each phase (leg) and redistribute
the loads as necessary.
6. Faulty voltage regulator Replace the voltage regulator (p. 28).
UNBALANCED PHASE CURRENTS
1. Unevenly distributed loads Measure output current in each phase (leg) and redistribute
the loads as necessary.
2. Improper generator connections Reconnect according to Figure 27 (p. 53).
3. Faulty stator windings Check stator winding resistances (p. 34).
4. Ground or short in load circuit Service the faulty equipment as necessary.

51
FIGURE 25. DC CONTROL SCHEMATIC

52
FIGURE 26. WIRING HARNESS DIAGRAM

3-PHASE GENERATORS
1-PHASE GENERATORS
53
FIGURE 27. GENERATOR RECONNECTION DIAGRAMS

Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Cummins and Onan are registered trademarks of Cummins Inc.
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MDKAL, MDKAA, MDKAB

Printed in U.S.A. 981−0524C

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POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE VESSEL

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Operation, Periodic Maintenance Schedule and

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PRE-START CHECKS Troubleshooting if the engine does not start on

* In this manual, “sea water” refers to floatation water.

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TABLE 3. PERIODIC MAINTENANCE SCHEDULE

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OIL DIPSTICK OIL FILL

OIL DRAIN HOSE OIL FILTER

FIGURE 4. OIL CHECK, FILL, DRAIN AND FILTER

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Replenish the normal loss of coolant by keeping the Pressure Cap

* In this manual, “sea water” refers to floatation water.

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SEA WATER COOLED

ZINC SEA WATER

TO HEAT THERMOSTAT V−BELT SEA WATER SEA COCK

SEA WATER HULL

FIGURE 5. TYPICAL HEAT EXCHANGER-TYPE COOLING SYSTEM

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WARNING Accidental starting can cause se-

2. Loosen the alternator pivot bolt first and then

3. Tighten belt tension by pivoting the alternator

4. Secure the belt guard or sound shield door and

WARNING Accidental starting can cause se-

WARNING Hot coolant is under pressure and

2. Remove the two thermostat housing bolts (Fig-

3. Clean off the gasket area and reassemble as

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A SIPHON BREAK IS REQUIRED WHEN MUFFLER

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1. Disconnect the negative (- ) cable(s) at the bat-

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FUEL STOP SOLENOID FUEL INJECTION PUMP

FIGURE 10. FUEL SYSTEM

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TO PRIME MORE THAN 20 SECONDS DISCONNECT ENGINE

USE TWO FLARE−NUT WRENCHES TO

OPEN LOW−PRESSURE BLEED

FIGURE 11. PRIMING THE FUEL SYSTEM

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