. Printed in U.S.A. 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. Safety Precautions SAFETY PRECAUTIONS.
MAINTENANCE SCHEDULE.MAINTENANCE PROCEDURES. Safety Precautions Thoroughly read the OPERATOR’S MANUAL Make sure all fasteners are secure and proper- before operating the genset. Safe operation and ly torqued.
Top performance can only be attained when Do not work on the genset when mentally or equipment is operated and maintained prop- physically fatigued or after having consumed erly. ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE Wear safety glasses while servicing batteries Never sleep in the boat while the genset is run- and do not smoke. Ning unless the boat is equipped with properly working carbon monoxide detectors. To reduce arcing when disconnecting or recon- necting battery cables, always disconnect the The exhaust system must be installed in accor. Information for California Genset Users provides important information for California genset users. The standard control panel and the routine mainte- nance items are shown in Figure 2.
Marine Engine service manager; and E. Murray, manager, Marine Engine. For Onan marine engines, this manual starting. Two-cylinder, four-cycle model is.
Onan is a registered trademark of Onan Corporation. NAMEPLATE LOCATED ON INNER SIDE OF CONTROL BOX 9.0MDKWB/60507D. OIL FILL OUTPUT VOLTAGE BATTERY ADJUST NEGATIVE (−) START SOLENOID OIL FILTER AIR INTAKE MUFFLER OIL DRAIN DRIP PAN GROUNDING STRAP FIGURE 2. GENERATOR SET COMPONENT LOCATIONS (MDKUB SHOWN) Redistribution or publication of this document, by any means, is strictly prohibited. Controls and Circuit Breakers The set controls and circuit breakers are located on Set-Mounted Controls and Breakers the front of the generator set, behind the front hous- Start/Stop/Preheat Switch: Starts and stops the ing panel.
See Figure 4. Generator set. Operates the engine cylinder preheaters. Optional Control/Meter Panel monitor oil pressure, coolant temperature, and DC battery voltage. The Starting and Stopping section An optional control panel includes a start/stop/pre- of this manual describes these meters and what heat switch, running time meter, and gauges that they should show during set operation.
- Section 1 Introduction ABOUT THIS MANUAL This manual provides information for MAJB marine generator sets. This is a complete service man- ual for the experienced service person.
- ABOUT THIS MANUAL This is the Operator’s Manual for the generator sets (gensets) listed on the front cover. Each operator. Numbers on the nameplate when contacting Onan for parts, service and product information. Who are trained and experienced in marine gen-set service. MODEL NUMBER: _____ SERIAL NUMBER: _____.
Check the engine oil level at the intervals shown in Table 2, later in this manual. The oil dipstick and fill MDKUB oil capacity: 3.78 liters (4 quarts) are located on the side of the engine (see Figure 5). MDKWB oil capacity: 4.73 liters (5 quarts) The dipstick is stamped with FULL and ADD to indi- cate the oil level in the crankcase. COOLANT The coolant level should be near the fill mark on the coolant overflow bottle fill cap. Do not check while OIL DIPSTICK the coolant is hot. The sudden release of hot pressur- WARNING FILL ized coolant can result in serious personal in- jury. FUEL CHECK 32 F (0 C), and during long periods of light engine load.
Carefully inspect the fuel system for leaks or corro- sion. Have any problems repaired immediately. Use low sulfur content fuel which has a cloud point at least 10 degrees below the lowest expected fuel Fuel presents the hazard of fire or WARNING temperature. Starting and Stopping EXHAUST GAS IS DEADLY!
Exhaust gases contain carbon monoxide, an odorless and colorless gas. Carbon monoxide is poisonous and can cause unconsciousness and death. Symptoms of carbon monoxide poisoning can include: Dizziness Throbbing in Temples Nausea Muscular Twitching Headache Vomiting Weakness and Sleepiness. Starting at Remote (Meter) Panel STOPPING If the optional remote panel with meters has been Before Stopping installed, monitor the oil pressure, water tempera- ture, and set DC voltage while the set is being started, and after it has run for roughly a minute. Run the genset at no load three to five minutes be- fore stopping. Wattage Requirements AC WATTAGE CAPACITY Electrical shock can cause severe WARNING personal injury or death. Appliances should be The AC power output from the generator will power in good working condition and be properly appliances and other equipment.
(The wattage re- grounded to provide additional protection from quirement of appliances and electrical equipment electrical shock. the breaker. If it trips again, a short circuit is indi- tion 981-0601) for information on isolating the gen- cated. Turn off the set and contact a qualified tech- set from utility-supplied power. Nician for assistance.
Connecting the generator set di- WARNING If the breaker does not trip, turn on only as many ap- rectly to the public utility or any other power. Operating Recommendations BREAK-IN PROCEDURE EXERCISE PERIOD Drain the crankcase oil after the first 35 hours of op- Infrequent use can result in difficult starting and eration. See the Maintenance section of this man- moisture condensation problems. This moisture is ual for the procedure. A result of the engine not being run long enough to reach normal operating temperature. Procedures section for instructions.
Sonal injury or death. Disconnect both genera- Consult an Onan service center if the generator set tor set starting battery cables, before perform- will be subjected to extremely hot or dusty condi- ing maintenance. Repair all leaks immediately. Able genset operator. If there is any doubt as to the correct performance of a procedure, consult your Fuel System Onan distributor. Certain procedures on the With the set running, inspect the fuel supply lines, Maintenance Schedule (brush replacement, return lines, filters, and fittings for leaks. Cleaning The Set Oil Filter Change Clean the generator set whenever dust and dirt be- Spin off the oil filter and discard it.
Thoroughly clean gin to accumulate. Dust and dirt can usually be re- the filter mounting surface.
Onan Marine Genset Service Manuals
Apply a thin film of oil to moved with a damp cloth. COOLING SYSTEM pressure cap and slowly fill the cooling system with the coolant mixture. The cooling system is drained before the set is shipped. It must be refilled before the genset is Exceeding the recommended fill CAUTION operated.
Cooling system capacity is listed in the rate can cause incomplete filling of the engine Specifications section. REFILL COOLANT COOLANT FILL HERE IF LOW COOLANT RECOVERY TANK CYLINDER BLOCK COOLANT DRAIN DRAIN HEAT TUBE EXCHANGER FIGURE 7. GENSET COOLING SYSTEM Flushing and Cleaning Flushing: After cleaning, or before filling the sys- tem with new coolant, drain the system and fill with clean water. Slide the alternator until the tension is Parts Manual).
The siphon valve is not part of the right. See Figure 8. Generator set; however, Onan provides a siphon Belt tension is correct when a finger pressure of 22 valve kit. FUEL SYSTEM Due to the precise tolerances of die- CAUTION sel injection systems, dirt or water in the system will cause severe damage to both the injection Use the best fuel available. Fuel quality is important pump and the injection nozzles. It is extremely for dependable performance and satisfactory en- important the fuel be kept clean and water free. INJECTION PUMP FUEL RETURN LINE FITTING FUEL INLET FITTING FROM FUEL TANK EXTERNALLY MOUNTED FUEL FILTER (SUPPLIED BY INSTALLER) FIGURE 9.
INJECTION PUMP FUEL SYSTEM Fuel Filter 1. Open the drain valve and bleed plug on the fuel filter assembly (Figure 10). Collect fuel in a suitable container and dispose of properly. Remove the bleed plug.
See Figure 4-5. Remove filter element from the head with the PLUG bowl connected. Clean the bowl, O-ring and O-ring gland. Lubricate the O-ring with clean diesel fuel and place it in the bowl gland.
After cleaning, flush the out- nance Schedule. This procedure should be per- side of the battery and the surrounding areas formed by an authorized Onan service technician. With clean water. Accidental starting of the generator 3. Identify the cable as positive (+) or negative (-) WARNING set can cause severe personal injury or death. Generator Set Storage OUT-OF-SERVICE PROTECTION 5. Plug exhaust outlets to prevent entrance of moisture, bugs, dirt, etc.
The lubricating qualities of No. 2 diesel fuel should protect the cylinders of a diesel engine at least 30 6. Clean and wipe the entire genset. Lightly coat days when the set is not being run. The DC control has a number of sensors that con- tinuously monitor the engine for low oil pressure, If a major problem is indicated, contact an Onan high coolant temperature and high exhaust tem- dealer or distributor for help or service.
Low Oil Pressure High Exhaust Temperature Remove dipstick and check oil level. If low, add oil The high exhaust temperature switch is mounted on to bring level up to full mark. Inspect engine exterior the exhaust elbow and closes on temperature rise for leaks and repair as necessary.
If you have difficulty in arranging for service or 3. For the name of your local Cummins /Onan or resolving a problem, please contact the dealer Onan-only distributor in the United States or coordinator or service manager at the nearest Canada, call 1-800-888-ONAN (this auto- Cummins/Onan distributor for assistance. Fuel consumption (No. 2 diesel fuel) liters/hour (gallons/hour) average @ half load: MDKUB @ 60 Hz. Record the service date and the meter (if equipped). DATE HOUR METER READING SERVICE PERFORMED / NOTES Record the name, address, and phone number of your authorized Onan service center.
Yamaha Marine Service Manual
Redistribution or publication of this document, by any means, is strictly prohibited. Information for California Genset Users These gensets meet the requirements of Califor- You should carefully review Operator (Owner), nia’s Exhaust Emissions Standards for 1995 and Installation and other manuals and information you later for Utility and Lawn and Garden Equipment receive with your genset. 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. Redistribution or publication of this document, by any means, is strictly prohibited.