Operator’s

Manual
MDKAV, MDKAW
MDKAZ, MDKBD
MDKBE, MDKBF
MDKBG

Printed in U.S.A. 06-02 981-0163B

Redistribution or publication of this document

by any means, is strictly prohibited.
 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

Redistribution or publication of this document

by any means, is strictly prohibited.
Table of Contents
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Fire Extinguisher Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Genset Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Remote Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Starting the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Stopping the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting Shore Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Loading the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
New or Re-Built Engine Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Exercising the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Cold Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Storing the Genset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Changing Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Draining / Changing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintaining Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
EMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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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 properly.
physically fatigued or after having consumed
alcohol or drugs.
The following symbols in this manual alert you to po-
tential hazards to operators, service personnel and • You must be trained and experienced to make
equipment. adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
alerts you to an immediate hazard vere personal injury or death.
which will result in severe personal injury or • Used engine oil has been identified by some
death. U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
WARNING alerts you to a hazard or unsafe inhale, or contact used oil or its vapors.
practice which can result in severe personal in-
jury or death. • Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
CAUTION alerts you to a hazard or unsafe
and dispose of used engine coolant in accor-
dance with local environmental regulations.
practice which can result in personal injury or
equipment damage. • Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
Electricity, fuel, exhaust, hot engine coolant, moving terials such as wood and cloth; Class B fires,
parts and batteries present hazards which can re- combustible and flammable liquid fuels and
sult in severe personal injury or death. gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
GENERAL PRECAUTIONS • Genset installation and operation must comply
• Keep children away from the genset. with all applicable local, state and federal codes
and regulations.
• Do not use evaporative starting fluids. They are
highly explosive. GENERATOR VOLTAGE IS DEADLY
• Do not step on the genset when entering or • Generator electrical output connections must
leaving the generator room. Parts can bend or be made by a trained and experienced electri-
break leading to electrical shorts or to fuel, cool- cian in accordance with applicable codes.
ant or exhaust leaks. • The genset must not be connected to shore
• To prevent accidental or remote starting while power or to any other source of electrical pow-
working on the genset, disconnect the nega- er. Back-feed to shore power can cause electric
tive (- ) battery cable at the battery. shock resulting in severe personal injury or
death and damage to equipment. An approved
• Let the engine cool down before removing the switching device must be used to prevent inter-
coolant pressure cap or opening the coolant connections.
drain. Hot coolant under pressure can spray
• Use caution when working on live electrical
and cause severe burns.
equipment. Remove jewelry, make sure cloth-
• Keep the genset, drip pan and compartment ing and shoes are dry, stand on a dry wooden
clean. Oily rags can catch fire. Gear stowed in platform or rubber insulating mat and use tools
the compartment can restrict cooling. with insulated handles.

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 ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE
• Never sleep in the boat while the genset is run- • Wear safety glasses.
ning unless the boat is equipped with properly • Do not smoke.
working carbon monoxide detectors.
• To reduce arcing when disconnecting or recon-
• The exhaust system must be installed in accor- necting battery cables, always disconnect the
dance with the genset Installation Manual and negative (- ) battery cable first and reconnect it
be free of leaks. last.
• Make sure the bilge is adequately ventilated MOVING PARTS CAN CAUSE SEVERE
with a power exhauster. PERSONAL INJURY OR DEATH
• Inspect for exhaust leaks every startup and af- • Do not wear loose clothing or jewelry near mov-
ter every eight hours of operation. ing parts such as PTO shafts, fans, belts and
pulleys.
• For more information about carbon monoxide
see American Boat and Yacht Council (ABYC) • Keep hands away from moving parts.
publication TH-22—Educational Information • Keep guards in place over fans, belts, pulleys,
About Carbon Monoxide. and other moving parts.

DIESEL FUEL IS COMBUSTIBLE FLAMMABLE VAPOR CAN CAUSE A

DIESEL ENGINE TO OVERSPEED
• Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas Flammable vapor can cause a diesel engine to
sharing ventilation with fuel tanks or equip- overspeed and become difficult to stop, resulting in
ment. Keep flames, sparks, pilot lights, arc-pro- possible fire, explosion, severe personal injury or
ducing equipment and all other sources of igni- death. Do not operate a diesel-powered genset
tion well away. in a flammable vapor environment created by
fuel spill, leak, etc. The owners and operators of
• Fuel lines must be secured, free of leaks and the genset are solely responsible for operating the
separated or shielded from electrical wiring. genset safely.

POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE BOAT

M-10

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Introduction
ABOUT THIS MANUAL

This is the operator’s manual for the generator sets

(gensets) listed on the front cover. Each operator
should study this manual carefully and observe all of
its instructions and safety precautions. Keep this
manual handy for ready reference.

Operation, Periodic Maintenance and Trouble-

shooting provide the instructions necessary for op-
erating the genset and maintaining good perfor-
mance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (Page 12). Emis-
sions (Page 34) includes information regarding
compliance with emissions regulations. 13.5MDKAZ-1955A
E000 123456

WARNING This genset is not a life support sys-

tem. It can stop without warning. Children, per-
sons with physical or mental limitations, and
pets could suffer severe personal injury or
death. A personal attendant, redundant power
or an alarm system must be used if genset op-
eration is critical.

MODEL IDENTIFICATION

When contacting an Onan
dealer for parts, ser-

RECORD NUMBERS HERE
vice or product information (see How to Obtain Ser-
vice, Page 35), be ready to provide the model and MODEL NUMBER:
serial numbers on the genset nameplate. Figure 1
illustrates the nameplate and its location. The num-
SERIAL NUMBER:
bers in the gray boxes are typical model and serial
numbers. Every character in these numbers is sig-
nificant. (The last character of the model number is
the specification letter, which is important for obtain- FIGURE 1. TYPICAL NAMEPLATE
ing the right parts.) Record the model and serial
numbers in the boxes in Figure 1 so that they are
easy to find when you need them.

Genuine Onan replacement parts are recom-

mended for best performance and safety.

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 FUEL RECOMMENDATIONS
High quality fuel is necessary for good performance
and long engine life. Use No. 2 diesel fuel (American
Society for Testing and Materials [ASTM]
Grade 2-D). The Cetane number should not be less
than 45 and sulfur content not more than 0.5 percent
(by weight). Where fuel is exposed to cold ambient
temperatures, use fuel that has a cloud point (tem-
perature at which wax crystals begin to form) at
least 10° F (6° C) degrees below the lowest ex-
pected fuel temperature. FIGURE 2. SAE VISCOSITY GRADE vs. AMBIENT
WARNING Diesel fuel is combustible and can
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 multi-
class ABC fire extinguisher handy.
ENGINE OIL RECOMMENDATIONS
Use API (American Petroleum Institute) perfor-
mance Class CH-4 engine oil or better. Also look for
the SAE (Society of Automotive Engineers) viscos-
ity grade. Referring to Figure 2, choose the viscosity
grade appropriate for the ambient temperatures ex-
pected until the next scheduled oil change. Multi-
grade oils such as SAE 15W-40 are recommended
for year-round use.
Synthetic motor oil is not recommended.

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 STARTING BATTERIES
The genset requires a 12 or 24 volt battery(ies) to
power its control and starting circuits. Reliable gen-
set starting and starter service life depend upon ad-
equate battery system capacity and maintenance.
See Specifications (Page 32) for battery require-
ments and Periodic Maintenance (Page 17) for bat-
tery care.

FIRE EXTINGUISHER PORT

The genset enclosure has a fire extinguisher port

accessible by breaking through the circle on the
warning label located as shown in Figure 3. Make
sure that the nozzle of the fire extinguisher that
will be used in the event of fire is smaller than
the circle so that it will fit through the port. The
fire extinguisher must be of the gaseous type.

In the event of fire:

1. DO NOT open the genset enclosure.
2. Shut down engines, generators and blowers.
3. Break through the circle on the label with the
nozzle and discharge the full contents of the fire
extinguisher.

FIGURE 3. FIRE EXTINGUISHER PORT

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 GENSET CONTROL PANEL starter disconnects and the engine is up to speed
and stays on while the genset runs.
The control panel (Figure 4) is located in the front,
upper left hand corner of the genset. Emergency Stop Switch - In an emergency push
OFF. Push ON after all necessary repairs to the gen-
Control Switch - This switch is used to prime the set and connected equipment have been made.
fuel system, start and stop the genset and display
DC Circuit Breaker - This circuit breaker protects
the shutdown codes.
the DC control circuits of the genset from short cir-
• Hold the switch in its START position to pre- cuits. Push the handle left to reset after all neces-
heat, crank and start the genset. (Preheat is the sary repairs have been made to the genset.
period of time prior to engine cranking when the
glow plugs preheat the combustion chambers. Hour Meter - The hour meter records genset oper-
The time is automatically varied by the genset ating time in hours. It cannot be reset.
controller on the basis of engine temperature.)
Engine Gauges (Optional)- These gauges moni-
• Press the switch to its STOP/PRIME position to tor engine oil pressure, coolant temperature and
stop the genset. battery voltage. They have green, yellow and red
• Hold the switch in its STOP/PRIME position to LEDs. GREEN indicates normal operation. YEL-
prime the fuel system (starts in 2 seconds). LOW and RED warn of abnormal engine conditions
requiring maintenance or service. RED is more se-
• See Troubleshooting (Page 24) about display- vere than YELLOW. See Periodic Maintenance
ing the shutdown codes. (Page 12).

Status Indicator Lamps- There are two LED (light Line Circuit Breakers - See Page 9.
emitting diode) lamps in the control switch. The am-
ber status lamp lights during priming, blinks rapidly REMOTE CONTROL PANEL
during pre-heat and cranking and goes out when the
engine is up to speed. If the genset shuts down ab- The boat probably has one or two remote control
normally, this lamp will slowly blink a code to indi- panels for starting and operating the genset. The
cate the cause of shutdown. See Troubleshooting gauges on Onan-supplied remote panels are like
(Page 24). The green status lamp lights after the the ones on the genset.

DC CIRCUIT BREAKER ENGINE GAUGES (OPTIONAL)

EMERGENCY STOP SWITCH HOUR METER CONTROL SWITCH & STATUS LAMPS

FIGURE 4. GENSET CONTROL PANEL

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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 boat
when the genset is running unless the cabin has a working carbon monoxide detector.

Look over the entire exhaust system and listen for leaks every time you start up the genset
and after every eight hours of operation. Shut down the genset immediately if there is a leak.
Do not run the genset until the leak has been repaired. The exhaust system must be installed
in accordance with the genset Installation Manual.

PRE-START CHECKS 2. For longer engine life, let the engine warm up
for two minutes before turning on air condition-
Conduct general inspections (Page 13) before the ers and other large appliances.
first start of the day and after every eight hours of op- 3. Check for water, coolant, fuel and exhaust
eration. Keep a log of maintenance and the hours leaks. Stop the genset immediately if there is a
run (Page 36) and perform any maintenance that leak. Repair fuel leaks immediately.
may be due. Perform maintenance required to re-
turn the genset to service if the boat has been in 4. Monitor the engine gauges if so equipped. Per-
storage (Page 11). Before each start: form maintenance or service as necessary if a
gauge indicates an abnormal engine condition.
1. Make sure all CO detectors on board are work- See Periodic Maintenance (Page 12).
ing properly.
5. If the genset fails to start, cranking will dis-
2. Check for swimmers that might be exposed to continue in 20 to 60 seconds, depending on
the engine exhaust. how cold the engine is, and the amber status
3. Turn off air conditioners and other large ap- lamp will blink Shutdown Code No. 4
pliances. (Page 26). See Troubleshooting (Page 24) if
the genset does not start after two or three tries.
PRIMING THE FUEL SYSTEM CAUTION Do not continue cranking and
risk burning out the starter or flooding the
If the genset ran out of fuel, prime the fuel system by engine (exhaust flow during cranking is too
holding the control switch at STOP/PRIME for low to expel water from the exhaust sys-
30 seconds. (The amber status lamp will light.) tem). Find out why the genset does not start
and make necessary repairs.
STARTING THE GENSET 6. If the genset shuts down, the amber status
1. Push and hold the control switch at START until lamp will blink one of the shutdown codes. See
the genset starts. The amber status lamp will Troubleshooting (Page 24).
blink rapidly. The amber status lamp will go out
and the green status lamp will light after the STOPPING THE GENSET
starter has disconnected and the engine is up
to speed. (Depending on how cold the engine Turn off air conditioners and other large appliances
is, preheat can take up to 15 seconds before and let the genset run for two minutes to cool down.
cranking starts.) Then touch the Control Switch to STOP.

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 EMERGENCY STOP
Push the EMERGENCY STOP SWITCH to OFF LINE CIRCUIT BREAKER HANDLES
(Page 7). After all necessary repairs have been PULL FORWARD FOR ON
made, push the switch to ON so that the genset can
be operated.
RESETTING CIRCUIT BREAKERS
If a circuit breaker in the main power distribution
panel of the boat or on the genset (Figure 5) trips,
either a circuit shorted or too many appliances were
running. Note that the genset may continue to run
after a circuit breaker trips.
If a circuit breaker trips, disconnect or turn off all
connected loads and reset the circuit breaker. (Push
the circuit breaker to OFF to reset it and then to ON
to reconnect the circuit.) If the circuit breaker trips
right away, either the electrical distribution system
has a short circuit or the circuit breaker is faulty. Call
a qualified electrician.
If the circuit breaker does not trip, reconnect or turn
on appliances one by one up to a total load that does
not exceed genset or circuit breaker rating. If a cir-
cuit breaker trips right away when an appliance is
FIGURE 5. LINE CIRCUIT BREAKER
connected, that appliance probably has a short.
Electrical appliances and tools must be used and
maintained properly and be properly grounded to
cause the line circuit breakers to trip when short cir-
cuits occur.
WARNING Short circuits in electrical ap-
pliances and tools can cause fire and electrical
shock leading to severe personal injury or
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re-
garding use, maintenance and proper ground-
ing.
CONNECTING SHORE POWER
If the boat has provisions for connecting shore pow-
er, it must also have an approved device to keep the
genset and shore power from being interconnected.
WARNING Backfeed to shore power can cause
electric shock resulting in severe personal inju-
ry or death and damage to equipment. The boat
must have an approved device to prevent the
genset from being interconnected with shore
power.

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 LOADING THE GENSET A genset equipped with an hydraulic pump can be
loaded with hydraulic as well as electrical loads at
the same time. It may be necessary to run fewer
The genset can power AC motors, air conditioners, electrical loads—or none at all—while powering
AC/DC converters and other appliances. How much hydraulic loads.
appliance load* can be powered depends upon the
genset power rating. The genset will shut down or its The genset is rated at standard barometric pres-
circuit breakers will trip if the sum of the loads ex- sure, humidity and temperature (ref. ISO 3046). Ei-
ceeds genset power. ther low barometric pressure (high altitude) or high
ambient temperature will decrease engine power. It
may be necessary to run fewer appliances un-
To avoid overloading the genset and causing shut- der such conditions.
downs, compare the sum of the loads of the ap-
TABLE 1. TYPICAL APPLIANCE LOADS
pliances that are likely to be used at the same time
Appliance Load (watts)
with the power rating of the genset. Use Table 1 or
the ratings on the appliances themselves to obtain Air Conditioner 1400-2000
the individual appliance loads. If the appliance is Battery Charger Up to 3000
marked in amps and volts only, multiply the amps DC Converter 300-700
times the volts to obtain the appliance load (watts). Refrigerator 600-1000
It may be necessary to run fewer appliances at Microwave Oven 1000-1500
the same time—the sum of the loads must not Electric Frying Pan or Wok 1000-1500
be greater than genset rating. Electric Stove Element 350-1000
Electric Water Heater 1000-1500
Electric Iron 500-1200
Note that the genset may shut down due to over-
Electric Hair Dryer 800-1500
load—even though the sum of the loads is less than
Coffee Percolator 550-750
genset rating—when a large motor or air conditioner
Television 200-600
is started or cycles on. The reason for this is that mo-
tor startup load is much larger than running load. It Radio 50-200
may be necessary to run fewer appliances when Electric Drill 250-750
large motors and air conditioners are running or Electric Broom 200-500
cycling on and off. Electric Blanket 50-200

* Appliance load and genset power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

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 NO-LOAD OPERATION Storing the Genset
1. Change the engine oil (Page 14) and attach a
Keep no-load operation to a minimum. During tag indicating viscosity grade (Page 5).
no-load operation cylinder temperatures drop to the
point where fuel does not burn completely, causing 2. Disconnect the battery cables (negative [- ]
fuel wetting and white smoke. It is best to run the first) from the battery (Page 17). Follow the
genset at 1/4 to 3/4 load (Page 10). manufacturer’s recommendations when stor-
ing the battery.
NEW OR RE-BUILT ENGINE CARE
WARNING Hot coolant is under pressure
Change the oil and oil filter after the first 50 hours of and can cause severe burns when loosen-
operation with a new or re-built engine (Page 14). ing the pressure cap. Let the engine cool
before loosening the pressure cap.
EXERCISING THE GENSET
3. Check coolant level and add as necessary
Exercise the genset at least 1 hour every month if (Page 18). Test the coolant mixture if freezing
use is infrequent. Run the genset at 1/4 to 3/4 load temperatures are possible and change if nec-
(Page 10). A single exercise period is better than essary.
several shorter periods. Exercising a genset drives
4. If freezing temperatures are expected, drain
off moisture, re-lubricates the engine, uses up fuel
the heat exchanger (Page 22), hoses and muf-
before it becomes stale and removes oxides from fler to prevent damage from freezing water.
electrical contacts and generator slip rings. The re-
sult is better starting, more reliable operation and 5. Clean and lightly oil parts that can rust.
longer engine life.
Returning the Genset to Service
COLD TEMPERATURE OPERATION
1. Check the oil tag on the genset and change the
Do not let raw water freeze in the heat exchanger oil (Page 14) if the viscosity is not appropriate
(Page 22) during cold weather when the genset is for the temperatures expected (Page 5).
not operating. Freezing water can damage the raw 2. Reconnect the battery cables (negative [- ] last)
water tubes in the heat exchanger. Engine coolant, (Page 17).
but not raw water, is protected from freezing. Drain
the heat exchanger if there is a danger of freezing. 3. Replace the raw water pump impeller if it was
installed more than a year ago (Page 23).
STORING THE GENSET 4. Perform the maintenance required (Page 12),
conduct the pre-start checks (Page 8) and
Proper storage is essential for preserving top gen-
prime the fuel system (Page 8).
set performance and reliability when the genset will
be idle for more than 120 days. 5. Start and run the genset (Page 8).

11 Redistribution or publication of this document

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Periodic Maintenance
Periodic maintenance is essential for good perfor- ever, warranty work must be completed by an au-
mance and long genset life. Use Table 2 as a guide thorized Onan dealer.
for normal periodic maintenance and record main-
tenance performed on Page 36.
WARNING Accidental or remote starting can
Maintenance, replacement or repair of emission cause severe personal injury or death. Discon-
control devices and systems may be performed by nect the negative (-) cable at the battery to pre-
any engine repair establishment or individual. How- vent starting while working on the genset.

TABLE 2. PERIODIC MAINTENANCE SCHEDULE

FREQUENCY
P
After Every Every Every Every Every a
first Day/ Month/ Year/ Year/ Every Every 5 years/ g
PROCEDURE 50 Hrs 8 Hrs 100 Hrs 200 Hrs 500 Hrs 800 Hrs 2 years 2000 Hrs e
General Inspection1 x 13
Check Engine Oil Level x 14
Check Battery x2 17
Check V-Belt Tension x3 22
Drain Fuel Filter x 16
Check Siphon Break x 21
Change Oil & Oil Filter x x 14
Change Fuel Filter x 16
Replace Raw Water Impeller x 23
Replace Zinc Anode x 18
Adjust Valve Lash x4 -
Change Coolant, Pressure
x 18
Cap & Thermostat
Check Generator Bearing x4 -
1 - Includes Oil Level, Coolant Level, Fuel System, Exhaust System and Battery Checks.
2 - See battery manufacturer’s recommendations.
3 - Check for slippage, cracking and wear.
4 - Must be performed by a trained and experienced mechanic (authorized Onan dealer) in accordance with the genset Service Manuals.

12 Redistribution or publication of this document

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 GENERAL INSPECTION signed to maintain coolant level; not to fill the sys-
tem. If the tank is empty, check for and repair any
Inspect the genset before the first start of the day coolant leaks and refill the system through the fill
and after every eight hours of operation. neck on the engine (Filling the System, Page 18).
Then refill the recovery tank up to the COLD mark.
Oil Level Use the recommended mixture of antifreeze
(Page 18).
Check engine oil level (Page 14).

Exhaust System Raw Water System

Inspect the exhaust system for leaks and loose Clean out the sea water strainer if necessary and
hose clamps at the exhaust manifold, exhaust el- make sure the sea cock is open for genset opera-
bow, muffler, water separator and hull fittings. Re- tion. Also, when a water/exhaust separator is pro-
place damaged sections of exhaust hose. vided (see Installation Manual), open the sea cock
for the water drain hose.
Check that all CO monitors are working properly.
Check for and replace hoses that leak or are dam-
WARNING EXHAUST GAS IS DEADLY! Do not aged.
operate the genset until all exhaust leaks have
been repaired. Battery Connections
Fuel System
Check the battery terminals and keep them clean
Check for leaks at hose, tube and pipe fittings in the and tight (Page 17). Loose or corroded terminals
fuel supply and return systems while the genset is have high electrical resistance, which can cause
running and while it is stopped. Check flexible fuel hard starting and short starter life.
hose for cuts, cracks, abrasions and loose hose
clamps. Make sure fuel lines do not rub against oth- Mechanical
er parts. Replace worn or damaged fuel line parts
before leaks occur. Replace hose with with USCG Look for mechanical damage. Start the genset and
TYPE A1 or ISO 7840-A1 fuel hose. look and listen for any unusual noises and vibra-
tions.
WARNING Fuel leaks can lead to fire. Repair
leaks immediately. Do not run the genset if it Check the genset mounting bolts to make sure they
causes fuel to leak. are secure.
Prime the fuel system (Page 8) if the genset ran
Check to see that the genset air inlet and outlet
out of fuel.
openings are not clogged with debris or blocked.
Coolant Level Check Keep the genset and generator compartment clean.

Keep the level of coolant in the recovery tank be- Monitor the engine gauges, if so equipped, whenev-
tween COLD and HOT. The recovery tank is de- er the genset is running.

13 Redistribution or publication of this document

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 CHECKING ENGINE OIL LEVEL WARNING Accidental or remote starting
can cause severe personal injury or death.
WARNING Crankcase pressure can blow out Disconnect the negative (-) cable at the bat-
hot engine oil causing severe burns. Always tery to prevent the engine from starting.
stop the genset before removing the oil dipstick 2. Remove the access door if the genset has an
or fill cap. enclosure. Unscrew the plug on the end of the
drain hose (Figure 6), if provided, and drain the
Shut off the genset before checking engine oil level oil into a suitable container. (Two wrenches are
and remove the access door if the genset has an en- necessary to keep from twisting the hose when
closure. loosening and tightening the plug.) If an oil
pump-out system is installed, follow the instruc-
1. Remove, wipe off and reinsert the oil level dip- tions provided.
stick (Figure 6 or 7). Remove the dipstick again
3. Secure the oil drain plug in the end of the hose
and check the oil level.
and secure the hose in its hanger.
2. Add or drain oil as necessary. See ENGINE OIL 4. Spin off the old oil filter (Figure 6 or 7) and wipe
RECOMMENDATIONS (Page 5). Keep the off the filter mounting surface. (A filter wrench
oil level between the high and low marks on the is available from Onan.) Remove the old gasket
end of the dipstick. It is not necessary to add oil if it does not come off with the filter.
between oil changes if the oil has not dropped
more than 1/3 of the way between the high and 5. Apply a film of oil to the filter gasket and partly
low marks. A full quart (0.9 liter) can be added fill the filter with oil so that it reaches engine
if the oil level is at the lower mark. parts sooner at startup. Spin the new filter on by
hand until the gasket just touches the mounting
CAUTION Too much oil can cause high oil pad and tighten 3/4 turn.
consumption. Too little oil can cause severe 6. Refill with the proper type (Page 5) and
engine damage. Keep the oil level between amount (Page 32) of engine oil and check the
the high and low marks on the dipstick. level (see CHECKING ENGINE OIL LEVEL).
3. Secure the access door if the genset has an en- 7. Secure the access door if the genset has an en-
closure. closure.
8. Dispose of the used oil and oil filter in accor-
CHANGING ENGINE OIL AND FILTER dance with local environmental regulations.

See Table 2 for scheduled oil change. WARNING U. S. state and federal agencies
have determined that contact with used engine
1. Run the genset under load until it is up to oper- oil can cause cancer or reproductive toxicity.
ating temperature, stop it and disconnect the Avoid skin contact and breathing of vapors. Use
negative (- ) battery cable at the battery. rubber gloves and wash exposed skin.

14 Redistribution or publication of this document

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 OIL LEVEL OIL FILL
DIPSTICK

OIL DRAIN FUEL FILTER OIl FILTER

HOSE

FIGURE 6. OIL AND FUEL SERVICE POINTS—MDKAV, MDKBG, MDKAW, MDKAZ

OIL LEVEL
DIPSTICK OIL FILL

OIL DRAIN ACCESS HOLE FUEL FILTER OIl FILTER

FIGURE 7. OIL AND FUEL SERVICE POINTS—MDKBD, MDKBE, MDKBF

15 Redistribution or publication of this document

by any means, is strictly prohibited.
 DRAINING / CHANGING FUEL FILTER the fuel supply valve, if provided, to prevent
loss of prime.
WARNING Diesel fuel is combustible and can 2. Remove the access door if the genset has an
cause severe personal injury or death. Do not enclosure. Drain the filter (about 1/2 cup [120
smoke near fuel tanks or fuel-burning equip- ml]) into a suitable container by removing the
ment or in areas sharing ventilation with such drain plug (bottom of filter).
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other 3. Re-install the drain plug and dispose of the
sources of ignition well away. Keep a multi- drain-off in accordance with local environmen-
class ABC fire extinguisher handy. tal regulations.
4. Secure the access door if the genset has an en-
Fuel Handling Precautions: Keep dirt, water and closure.
other contaminants from entering the fuel system
and corroding or clogging fuel injection compo- Changing Fuel Filter: See Table 2 for scheduled
nents. The genset has a water separator type of fuel filter change. Change the filter if the engine lacks
filter (Figure 6 or 7). The fuel supply system should power.
also have a water separator and filter. 1. Disconnect the negative (- ) cable at the battery
to prevent the engine from starting and close
Humid air condenses on the walls of fuel tanks and the fuel supply valve, if provided, to prevent
is the primary source of water in fuel. Water clogs loss of prime.
fuel passages by freezing and causes corrosion by
forming sulfuric acid with the sulfur in the fuel. Keep- 2. Remove the access door if the genset has an
ing fuel tanks full reduces condensation by reducing enclosure. Spin off the old filter and dispose of
the area on which condensation can take place. it in accordance with local environmental regu-
lations.
WARNING Accidental or remote starting can 3. Clean the contact surface on the filter base, lu-
cause severe personal injury or death. Discon- bricate the new filter gasket and spin the new
nect the negative (-) cable at the battery to pre- filter on hand tight.
vent the engine from starting.
4. Prime the engine for at least 30 seconds
Draining Water and Sediment: Drain water and (Page 8) to fill the new filter. Run the genset
sediment more often than scheduled (Table 2) if fuel and check for leaks. Tighten the filter by hand,
quality is poor or condensation cannot be avoided. if necessary.
1. Disconnect the negative (- ) cable at the battery 5. Secure the maintenance access door if the
to prevent the engine from starting and close genset has an enclosure.

16 Redistribution or publication of this document

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 MAINTAINING BATTERY AND BATTERY
CONNECTIONS
BATTERY CABLE TERMINALS ON GENSET
WARNING Flames, sparks or arcing at battery
terminals, light switches or other equipment
can ignite battery gas causing severe personal
injury — Ventilate the battery area before work-
ing on or near the battery — Wear safety glasses
— Do not smoke — Switch a work lamp ON and
OFF away from the battery — Do not disconnect
the battery cables while the genset is running or
a battery charger is on — Always disconnect the
negative (-) cable first and reconnect it last.
See Table 2 for scheduled maintenance. Follow the
battery manufacturer’s instructions. Have the bat-
tery charging system serviced if DC system voltage
is consistently low or high. Always:
1. Keep the battery case, terminals and cables
clean and dry and the terminals tight at the bat-
tery and at the genset (Figure 8).
2. Remove battery cables with a battery terminal
puller.
3. Make sure which terminal is positive (+) and
FIGURE 8. BATTERY CABLE TERMINALS
which is negative (- ) before making battery
connections. Always remove the negative (- )
cable first and reconnecting it last to reduce
arcing.
4. Follow the manufacturer’s recommendations
when storing the battery. Disconnect the bat-
tery so that it does not discharge through the
genset control during storage.

17 Redistribution or publication of this document

by any means, is strictly prohibited.
 ENGINE COOLING SYSTEM 1. Disconnect the negative (- ) cable at the battery
to prevent the engine from starting, let the en-
gine cool and remove the front and back access
Cooling System Overview doors if the genset has an enclosure.
WARNING Accidental or remote starting
The engine is cooled by a pressurized, closed-loop
liquid cooling system (Figure 9 or 10). Coolant is can cause severe personal injury or death.
pumped through passages in the engine block, Disconnect the negative (-) cable from the
head and exhaust manifold by a belt-driven pump battery to prevent the engine from starting.
and is cooled in a heat exchanger mounted on the WARNING Hot coolant is under pressure
base pan or in a keel cooler. The exhaust manifold and can cause severe burns when loosen-
also serves as the engine coolant reservoir. ing the pressure cap. Let the engine cool
before loosening the pressure cap.
If the genset has a heat exchanger and/or exhaust-
water mixer, the engine is equipped with a gear-driv- 2. Remove the coolant pressure cap.
en raw water pump. The raw water cools the heat
exchanger and/or exhaust gases and exits the boat 3. Open the block and heat exchanger drain
through the exhaust system. cocks (Figure 9 or 10) and collect the used
coolant in containers for proper disposal. See
the manufacturer’s instructions regarding how
Recommended Coolant Mixture to drain a keel cooler, if the boat is so equipped.
Use the best quality ethylene glycol antifreeze solu-
tion available. It should be fully formulated with rust Coolant Hoses: Check for and replace hoses that
inhibitors and coolant stabilizers. Use fresh water leak or are damaged.
that is low in minerals and corrosive chemicals. Dis-
tilled water is best. Unless prohibited by shipping Pressure Cap: See Table 2 for scheduled replace-
regulations, the genset is shipped with the recom- ment. The pressure cap is necessary for optimal en-
mended 50/50 mixture of water and ethylene glycol, gine cooling and reduced coolant loss.
which is good for -34° F (-37° C). See Page 32 re-
garding coolant capacity. Cleaning and Flushing the System: Use radiator
cleaning chemicals to clean and flush the cooling
WARNING Ethylene glycol antifreeze is con- system before refilling with fresh coolant. Follow the
sidered toxic. Dispose of it according to local cleaner manufacturer’s instructions.
regulations for hazardous substances.
CAUTION Filling a hot engine with cold water
Replenishing Normal Coolant Loss can cause cracks in the manifold, head and
block. Follow the manufacturer’s instructions
Keep the level of coolant in the coolant recovery for cleaning and flushing.
tank between COLD and HOT. The recovery tank is
designed to maintain coolant level; not to fill the sys- Filling the System: Close the block and heat ex-
tem. If the tank is empty, check for and repair any changer drain cocks and fill the system through the
coolant leaks and refill the system through the fill engine fill neck. The system will fill only as fast as the
neck on the engine. Then refill the recovery tank up air can escape. Fill to the bottom of the fill neck. Start
to the COLD mark. Use the recommended coolant and run the engine for a couple of minutes to dis-
mixture. lodge air pockets and shut it down. Add as much
coolant as necessary and secure the pressure cap.
Changing Coolant Then refill the recovery tank up to the COLD mark.

See Table 2 for scheduled maintenance. CAUTION Low coolant level can cause severe
engine damage. Make sure the system is full.
Draining the System: Have towels and containers
ready to wipe up, collect and properly dispose of the Secure the access door if the genset has an enclo-
coolant. sure.

18 Redistribution or publication of this document

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 OPTIONAL LOW COOLANT
LEVEL SENSOR LOCATION

COOLANT
THERMOSTAT

COOLANT PUMP

RAW WATER PUMP

RAW WATER FLOW SENSOR

RAW WATER IN FROM

BULKHEAD FITTING ON EXHAUST MANIFOLD & COOLANT RESERVOIR
RIGHT OR LEFT SIDE WITH PRESSURE CAP AND COOLANT FILL
NECK. FILL NECK HAS HOSE BARB FOR
CONNECTING COOLANT RECOVERY TANK

EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT OR
LEFT SIDE

RAW WATER TO
EXHAUST-WATER MIXER—MAY
HAVE BEEN REPLACED WITH
HOSES TO SIPHON BREAK
(SEE INSTALLATION MANUAL)

BLOCK DRAIN COCK

(COOLANT)

COOLANT RAW WATER CLEANOUT

DRAIN COCK COVER (BOTH ENDS)
COOLANT
ZINC RAW WATER DRAIN PLUG
ANODE (BOTH ENDS) RAW WATER

FIGURE 9. ENGINE COOLING SYSTEM—MDKAV, MDKBG, MDKAW, MDKAZ

19 Redistribution or publication of this document

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 RAW WATER TO PUMP FROM COOLANT RESERVOIR WITH PRESSURE CAP AND
BULKHEAD FITTING ON COOLANT FILL NECK. FILL NECK HAS HOSE BARB
RIGHT OR LEFT SIDE FOR CONNECTING COOLANT RECOVERY TANK

LOCATION, OPTIONAL LOW

COOLANT LEVEL SENSOR

COOLANT
THERMOSTAT
HOUSING

COOLANT
TEMPERATURE
SENSOR
RAW
WATER
PUMP
COOLANT
PUMP PULLEY
RAW WATER FROM HEAT
EXCHANGER TO EXHAUST-WATER
MIXER—MAY HAVE BEEN REROUTED LOCATION, BLOCK
THROUGH A SIPHON BREAK DRAIN COCK
(SEE INSTALLATION MANUAL) (COOLANT)

RAW WATER FLOW SWITCH

(IN PUMP-TO-HEAT EXCHANGER HOSE) ZINC ANODE

EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT
OR LEFT SIDE

RAW WATER CLEANOUT COVER

COOLANT DRAIN COCK (BOTH ENDS—MAKE SURE TO COOLANT
& RAW WATER PLUGS RECONNECT GROUND STRAP ON
(UNDERNEATH) THIS END WITH COVER SCREW) RAW WATER

FIGURE 10. ENGINE COOLING SYSTEM—MDKBD, MDKBE, MDKBF

20 Redistribution or publication of this document

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Siphon Break
WARNING Bypassing a siphon break or failing
to maintain it can lead to engine flooding and
damage to the engine not covered under War-
ranty.
See Table 2 for scheduled maintenance. A siphon
break is installed when the exhaust-water mixer is
below the water line. If of a spring-loaded valve de-
sign, check for free movement of the plunger. Re-
place the device if the plunger does not move freely
or the body is encrusted with deposits from leakage
THERMOSTAT
past the valve seat. If of the bleed-vent type, check
that the vent hose is properly connected on both
ends. If the vent is connected to a through-hull fit-
ting, check for normal water flow whenever the en-
gine is running. See the Installation Manual for more
information regarding siphon breaks.
Replacing the Thermostat
See Table 2 for scheduled replacement. Referring
to Figure 11, replace the thermostat as follows:
1. Disconnect the negative (- ) cable at the battery
to prevent the engine from starting, let the en-
gine cool and remove the front and back access
doors if the genset has an enclosure. FIGURE 11. THERMOSTAT
WARNING Accidental or remote starting
can cause severe personal injury or death.
Disconnect the negative (-) cable from the
battery to prevent the engine from starting.
WARNING Hot coolant is under pressure
and can cause severe burns when loosen-
ing the pressure cap. Let the engine cool
before loosening the pressure cap.
2. Remove the coolant pressure cap.
3. Remove the two thermostat housing bolts and
pull off the housing, thermostat and gasket. The
hose does not need to come off.
4. Clean off the gasket area and install the new
thermostat and gasket. Apply Three Bond 1215
liquid sealant or equivalent to the top side of the
gasket.
5. Replenish any lost coolant, secure the pres-
sure cap and any doors and panels removed
and reconnect the battery cables (negative [- ]
last).

21 Redistribution or publication of this document

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Adjusting V-Belt Tension
TENSION
Referring to Figure 12, readjust belt tension as fol- ADJUSTING
lows: BOLT
WARNING Accidental or remote starting can
cause severe personal injury or death. Discon-
nect the negative (-) cable at the battery to pre-
vent the engine from starting.
1. Disconnect the negative (- ) cable at the battery ALTERNATOR
to prevent the engine from starting. PIVOT BOLT

2. Remove the belt guard or the access doors and

top panel if the genset has an enclosure.
3. Loosen the alternator pivot bolt first and then
the adjusting bracket bolt on top.
4. Pivot the alternator out to tighten belt tension.
Hold tension by tightening the tension adjusting
bolt and check it by applying 20 pounds (10 kg)
to the middle of the pulley span. Belt tension is
correct when deflection is 0.4 inch (10 mm).
Tighten the alternator bolts when tension is cor-
rect.
0.4 INCH (10 MM)
5. Tighten the bolts, secure the belt guard or pan- DEFLECTION @
els and doors and reconnect the battery cables 20 LBS (10 KG)
(negative [- ] last).
Replacing the V-Belt When PTO Equipped
FIGURE 12. ADJUSTING V-BELT TENSION
A special belt replacement kit must be used when
the genset is equipped with a PTO. The kit includes
a tool to keep the flexible coupling from twisting dur-
ing assembly/disassembly. The coupling has to be
disassembled so that the belt can be looped around
the crank pulley. Follow the instructions in the kit.
Heat Exchanger and Zinc Anode
Both ends of the heat exchanger (Figure 9) have
raw water drain plugs and cleanout covers. Clean
the raw water tubes if the engine keeps shutting
down (Code No.1) or the engine gauge indicates
abnormally high engine temperatures. Drain the
heat exchanger if there is a danger of freezing when
the genset is not running or is in storage. (Freezing
water can damage the raw water tubes in the heat
exchanger. Engine coolant, but not raw water, is
protected from freezing.)
Replace the zinc anode as recommended (Table 2).
Use thread sealant on the zinc plug and drain plugs
and replace the clean out cover gaskets if the old
ones are torn or otherwise damaged.

22 Redistribution or publication of this document

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Replacing the Raw Water Pump Impeller
See Table 2 for scheduled replacement. Have tow- COVER O-RING
els and containers ready and avoid spilling raw wa-
ter on the electrical components below the pump.
Referring to Figure 13 replace the impeller as fol-
lows:
FLEXIBLE
WARNING Accidental or remote starting can IMPELLER
cause severe personal injury or death. Discon-
nect the negative (-) cable at the battery to pre-
vent the engine from starting.
1. Disconnect the negative (- ) cable at the battery
to prevent the engine from starting, let the en-
gine cool and close the sea cock.
TO HEAT
2. Remove the access door if the genset has an EXCHANGER
enclosure. OR EXHAUST-
WATER MIXER
3. Remove the impeller cover and O-ring.
4. Use two pliers to grip vanes on opposite sides
FROM
if the impeller is difficult to remove. It will be nec- SOURCE
essary to check for and cleanout pieces of the
impeller from the heat exchanger if vanes have
broken off.
5. Install the new impeller. It helps to twist the im- IMPELLER ROTATION
AND VANE INCLINATION
peller clockwise (the way it turns) while squeez-
ing it into the housing.
6. 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.
7. If the sea water strainer is above the water line, FIGURE 13. REPLACING RAW WATER IMPELLER
fill it for faster prime and secure its cover.
8. Open the sea cock, reconnect the battery
cables (negative [- ] last) and start the genset.
The genset will shut down within 8 seconds if
there is no raw water flow and the amber status
lamp will blink shutdown Code No. 7 (Page 27).
If it shuts down, find out why, remove any block-
age and restart the genset.
9. Secure the access door if the genset has an en-
closure.

23 Redistribution or publication of this document

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Troubleshooting
TABLE 3 lists the shutdown codes in numerical or- • Two blinks indicate shutdown due to low oil
der along with step-by-step corrective actions. If you pressure.
are unable to resolve the problem after taking the
• Three blinks indicate shutdown due to a condi-
corrective actions suggested, contact an authorized
tion normally requiring service by a trained and
Onan dealer. See How to Obtain Service (Page 35).
experienced person. Before assistance ar-
rives, you may be asked to help by accessing
First note the following: the second-level, two-digit shutdown code. To
• Maintaining engine oil and coolant levels, do so, press STOP once. The two-digit code
cleaning the raw water strainer, keeping battery consists of 1 to 6 blinks, a brief pause, and then
connections clean and tight, watching the fuel 1 to 9 blinks. The first set of blinks represents
gauge and not overloading the genset will pre- the tens digit and the second set of blinks the
vent most shutdowns. units digit of the shutdown code number. For
example, Shutdown Code No. 23 blinks as fol-
• When the genset and propulsion engines share lows:
a common fuel tank, the fuel dip tubes are usu-
blink-blink—pause—blink-blink-blink—long pause—repeat
ally arranged so that the genset will run out of
fuel first. Marking the genset empty point on the • Four blinks indicate shutdown due to a failure
fuel gauge will make it easier to tell when to stop to start within the time allowed for cranking.
the genset before running it out of fuel.
• Seven blinks indicate shutdown due to a loss
of raw water flow for engine and exhaust cool-
SHUTDOWN CODES ing.
The genset controller provides extensive diagnos- Blinking of the shutdown code continues for five
tics by causing the amber status lamp on the control minutes and stops. Pressing STOP three times re-
switch to blink. Following a shutdown, the indicator stores blinking. (If you press STOP again, blinking
lamp will blink 1, 2, 3, 4 or 7 times, pause, and then stops entirely and you have to start over by pressing
repeat the blinking. The number of blinks is the STOP three times.)
shutdown code.
Note: The last shutdown logged will blink, even
• One blink indicates shutdown due to high en- though the condition that caused shutdown has
gine temperature. been serviced.

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 TABLE 3. TROUBLESHOOTING
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

NO POWER—GENSET RUNNING, RUN LAMP ON

(Line circuit breaker OFF or tripped)
Corrective Action:
1. Turn on or reset the line circuit breaker on the genset (Page 9).
2. Turn on or reset the line circuit breakers on the main distribution panel in the boat.

STARTER ENGAGES-DISENGAGES
(Battery voltage dips below 6 volts while cranking—low battery charge, poor connections, long cables)
Corrective Action:
1. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and gen-
set (Page 17).
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.
3. Increase battery cable size or run parallel cables.

RUN-DOWN STARTING BATTERY

(Marginal battery, connections, or charging system or, parasitic loads)
Corrective Action:
1. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and gen-
set (Page 17).
2. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

ENGINE CRANKS, STARTS, ACCELERATES, BUT STOPS WHEN SWITCH LET GO

(Open field or open or grounded quadrature circuit)
Corrective Action: See an authorized Onan dealer.

NO LIGHTS, NO RESPONSE
(Poor connections, faulty wiring or dead battery)
Corrective Action:
1. Try the genset Control Switch if the remote Control Switch does not work, and vice versa.
2. Clean and tighten the positive (+) and negative (- ) battery cable connections at the battery and gen-
set (Page 17).
3. Recharge or replace the battery. Refer to the battery manufacturer’s recommendations.

25 Redistribution or publication of this document

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 TABLE 3. TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

HIGH ENGINE TEMPERATURE—CODE NO. 1

(First-level shutdown—Engine coolant temperature exceed design limit)
Corrective Action:
1. Add coolant as necessary and repair leaks (Page 18).
2. Replace the engine thermostat, which might not be opening fully (Page 21).
3. Clean the raw water tubes in the heat exchanger, which might be clogged with scale (Page 22).
4. Flush the coolant system to remove coolant passage fouling (Page 18).

LOW OIL PRESSURE—CODE NO. 2

(First-level shutdown—Low oil pressure)
Corrective Action: Add engine oil or drain excess oil, as necessary (Page 14).

SERVICE CHECK—CODE NO. 3

(First-level shutdown—Indicates presence of second-level shutdown)
Corrective Action: Check the second-level shutdown code by pressing STOP once. The second-level
shutdown code will have two-digits. The shutdowns are listed below in numerical order.

OVERCRANK—CODE NO. 4
(First-level shutdown—Cranking exceeded 20 to 60 seconds [temperature dependent] without start)
Corrective Action:
1. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)
2. Open any closed fuel valves.
3. Remove any blockage in the combustion air inlet (front grille) or exhaust system.
4. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction.
5. Drain and/or replace the fuel filter (Page 16) and prime the fuel system (Page 8).
6. Drain and/or replace fuel supply system filters and prime the fuel system (Page 8).

26 Redistribution or publication of this document

by any means, is strictly prohibited.
 TABLE 3. TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

LOSS OF RAW WATER FLOW—CODE NO. 7

(First-level shutdown—Low raw water pressure in heat exchanger)
Corrective Action:
1. Open the sea cock.
2. Close the sea cock and clean the sea water strainer. If the strainer is above the water line, fill it with
water to assist priming. Secure the strainer cover and reopen the sea cock.
3. Reconnect or replace any disconnected or leaking raw water hoses (Page 19).
4. Remove any blockage from the strainer on the through-hull fitting on the bottom side of the hull.
5. Replace the raw water impeller (Page 23).

OVERVOLTAGE—CODE NO. 12
(Controller unable to maintain rated voltage)
Corrective Action: See an authorized Onan dealer.

UNDERVOLTAGE—CODE NO. 13
(Controller unable to maintain rated voltage)
Corrective Action: Reduce the number of connected appliances, especially when air conditioners and
battery chargers are running.

OVERFREQUENCY—CODE NO. 14
(Engine governor unable to maintain rated frequency)
Corrective Action:
1. If the line circuit breaker or any other circuit breaker has tripped, start the genset before resetting
the breaker. (Frequency can overshoot when a circuit breaker trips under load.) If the genset contin-
ues to run, turn off or disconnect all loads, reset the breaker and bring the loads on one at a time
without overloading the genset.
2. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction.
3. Prime the fuel system to remove air in the fuel lines (Page 8).

27 Redistribution or publication of this document

by any means, is strictly prohibited.
 TABLE 3. TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

UNDERFREQUENCY—CODE NO. 15
(Engine governor unable to maintain rated frequency)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)
3. Remove any blockage in the combustion air inlet (front grille) or exhaust system.
4. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction.
5. Drain and/or replace the fuel filter (Page 16) and prime the fuel system (Page 8).
6. Drain and/or replace fuel supply system filters and prime the fuel system (Page 8).

OVER-PRIME—CODE NO. 17
(Prime mode exceed 5 minutes)

Corrective Action: Check for and remove any object that may be holding either control switch (remote
or local) in the prime position.

GOVERNOR OVERLOAD—CODE NO. 22

(Maximum allowable time at full-duty cycle was exceeded)
Corrective Action:
1. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)
3. Remove any blockage in the combustion air inlet (front grille) or exhaust system.
4. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction.
5. Drain and/or replace the fuel filter (Page 16) and prime the fuel system (Page 8).
6. Drain and/or replace fuel supply system filters and prime the fuel system (Page 8).

FAULTY OIL PRESSURE SENDER—CODE NO. 23

(Controller sensed grounded sender)
Corrective Action: See an authorized Onan dealer.

FAULTY TEMPERATURE SENDER—CODE NO. 24

(Controller sensed open sender)
Corrective Action: See an authorized Onan dealer.

28 Redistribution or publication of this document

by any means, is strictly prohibited.
 TABLE 3. TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

LOSS OF VOLTAGE SENSE—CODE NO. 27

(Controller unable to sense output voltage)
Corrective Action: See an authorized Onan dealer.

HIGH BATTERY VOLTAGE—CODE NO. 29

(Battery system at more than 19.2 volts if 12 VDC system, or 38.4 volts if 24 volt system)
Corrective Action:
1. Check battery bank connections and reconnect if necessary to supply 12 volts or 24 volts, as ap-
propriate.
2. Select a lower battery boost charge rate.

CONTROL CARD FAILURE—CODE NO. 35

(Microprocessor EEPROM error during self-test)
Corrective Action: See an authorized Onan dealer.

ENGINE STOPPED—CODE NO. 36

(Engine stopped without command by controller)
Corrective Action:
1. Open any closed fuel supply valves.
2. Check the fuel tank and fill as necessary. (Note: The arrangement of pickup tubes in the fuel supply
tank probably is such that the genset will run out of fuel before the propulsion engines.)
3. Check for mechanical damage and service as necessary.
4. Remove any blockage in the combustion air inlet (front grille) or exhaust system.
5. Tighten loose fuel line fittings so that air cannot be drawn in by genset lift pump suction.
6. Drain and/or replace the fuel filter (Page 16) and prime the fuel system (Page 8).
7. Drain and/or replace fuel supply system filters and prime the fuel system (Page 8).

INVALID GENSET CONFIGURATION—CODE NO. 37

(Controller cannot determine genset operating parameters)
Corrective Action: See an authorized Onan dealer.

29 Redistribution or publication of this document

by any means, is strictly prohibited.
 TABLE 3. TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

FIELD OVERLOAD—CODE NO. 38

(High field voltage induced by high rotor temperature or low power factor loads)
Corrective Action:
1. Remove blockages to generator air flow at the front inlet grill and right side, if enclosed.
2. Reduce the number of appliances running at the same time, especially those with high motor starting
loads such as air conditioners.
3. Have air conditioners and other appliances checked for proper operation. (A locked compressor ro-
tor can cause very low power factor.)

GROUNDED ROTOR—CODE NO. 41

(F+ grounded)
Corrective Action: See an authorized Onan dealer.

PROCESSOR FAILURE—CODE NO. 42

(Microprocessor ROM error during self-test)
Corrective Action: See an authorized Onan dealer.

PROCESSOR FAILURE—CODE NO. 43

(Microprocessor RAM error during self-test)
Corrective Action: See an authorized Onan dealer.

PROCESSOR FAILURE—CODE NO. 48

(Controller unable to sense field voltage)
Corrective Action: See an authorized Onan dealer.

HIGH EXHAUST TEMPERATURE—CODE NO. 58

(Exhaust temperature exceeded design limits)
Corrective Action:
1. Check for and reconnect or replace any disconnected or leaking raw water hoses (Page 19).
2. Check for a and replace a worn raw water impeller(Page 23).

30 Redistribution or publication of this document

by any means, is strictly prohibited.
 TABLE 3. TROUBLESHOOTING (CONT.)
WARNING Some genset service procedures present hazards that can result in severe per-
sonal injury or death. Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards should perform genset service. See Safety Precautions.
Accidental or remote starting can cause severe personal injury or death. Before removing a
panel or access door, disconnect the negative (-) cable from the battery to prevent the engine
from starting.

LOW COOLANT LEVEL—CODE NO. 59

(Exhaust temperature exceeded design limits)
Corrective Action: Add coolant as necessary and repair leaks (Page 18).

EMERGENCY SHUTDOWN—CODE NO. 61

(Genset was shut down by a fire suppression system or other external control)
Corrective Action: Make all necessary repairs to the genset and connected equipment and reset the
external control which shut down the genset.

31 Redistribution or publication of this document

by any means, is strictly prohibited.
Specifications
MDKAV MDKBG MDKAW MDKAZ
ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.
Alternator Cooling Air Flow: 60 Hz 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min)
50 Hz 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min)
FUEL CONSUMPTION:
60 Hz: Full Load 0.8 gph (3.0 liter/hr) 0.8 gph (3.0 liter/hr) 1.0 gph (3.8 liter/hr) 1.2 gph (4.5 liter/hr)
Half Load 0.5 gph (1.9 liter/hr) 0.5 gph (1.9 liter/hr) 0.6 gph (2.3 liter/hr) 0.7 gph (2.7 liter/hr)
50 Hz: Full Load 0.7 gph (2.7 liter/hr) 0.7 gph (2.7 liter/hr) 0.8 gph (3.0 liter/hr) 0.9 gph (3.4 liter/hr)
Half Load 0.4 gph (1.5 liter/hr) 0.4 gph (1.5 liter/hr) 0.5 gph (1.9 liter/hr) 0.5 gph (1.9 liter/hr)
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing
Model D1105 D1105 V1305 V1505
Number of Cylinders 3 3 4 4
Displacement 68.58 in3 (1124 cm3) 68.58 in3 (1124 cm3) 81.47 in3 (1335 cm3) 91.44 in3 (1499 cm3)
Bore 3.07 in (78 mm) 3.07 in (78 mm) 2.99 in (76 mm) 3.07 in (78 mm)
Stroke 3.09 in (78.4 mm) 3.09 in (78.4 mm) 2.90 in (73.6 mm) 3.09 in (78.4 mm)
Compression Ratio 22:1 22:1 22:1 22:1
Firing Order (Clockwise Rotation) 1-2-3 1-2-3 1-2-4-3 1-2-4-3
Fuel Injection Timing 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC

Valve Lash (cold) 0.0071 - 0.0087 in 0.0071 - 0.0087 in 0.0071 - 0.0087 in 0.0071 - 0.0087 in
(0.18 - 0.22 mm) (0.18 - 0.22 mm) (0.18 - 0.22 mm) (0.18 - 0.22 mm)
Lube Oil Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 4.5 quart (4.3 liter) 4.5 quart (4.3 liter)
Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPT
Coolant Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 5.3 quart (5.0 liter) 5.3 quart (5.0 liter)
Coolant Flow Rate: 60 Hz 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9liter/min)
50 Hz 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min)
Raw Water Flow Rate: 60 Hz 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min)
50 Hz 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min)
Combustion Air Flow: 60 Hz 30 cfm (0.85 m3/min) 30 cfm (0.85 m3/min) 36 cfm (1.02 m3/min) 41 cfm (1.16 m3/min)
50 Hz 25 cfm (0.71 m3/min) 25 cfm (0.71 m3/min) 30 cfm (0.85 m3/min)) 34 cfm (0.96 m3/min)
Heat Rejection to Ambient: 60 Hz 200 Btu/min (50 kcal/min) 200 Btu/min (50 kcal/min) 230 Btu/min (58 kcal/min) 280 Btu/min (71 kcal/min)
50 Hz 179 Btu/min (45 kcal/min) 179 Btu/min (45 kcal/min) 190 Btu/min (48 kcal/min) 210 Btu/min (53 kcal/min)
CONNECTIONS:
Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)
Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female
Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female
Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)
Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
KEEL COOLING AND DRY EXHAUST:
Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)
Heat Rejection to Coolant: 60 Hz 950 Btu/min (239 kcal/min) 950 Btu/min (239 kcal/min) 1220 Btu/min (307 kcal/min) 1420 Btu/min (358 kcal/min)
50 Hz 780 Btu/min (197 kcal/min) 780 Btu/min (197 kcal/min) 980 Btu/min (247 kcal/min) 1160 Btu/min (292 kcal/min)
Dry Exhaust Outlet 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts* 12 volts* 12 volts*
Min CCA Rating - SAE @ 32° F (0° C) 360 amps 360 amps 500 amps 500 amps
Battery Charging 5 amps 5 amps 5 amps 5 amps
SIZE, WEIGHT, NOISE:
Without Enclosure
Dry Weight 555 lbs (252 kg) 525 lbs (238 kg) 640 lbs (290 kg) 640 lbs (290 kg)
Dimensions: L x W x H 35.9 x 22.3 x 23.0 in 32.4 x 18.9 x 22.1 in 40.7 x 22.3 x 23.0 in 40.7 x 22.3 x 23.0 in
(911 x 566 x 585 mm) (479.1 x 822.6 x 560.9 mm) (1033 x 566 x 585 mm) (1033 x 566 x 585 mm)
With Enclosure
Noise 66 dB(A) @ 60HZ - 66 dB(A) @ 60HZ 66 dB(A) @ 60HZ
Dry Weight 600 lbs (272 kg) 695 lbs (315 kg) 695 lbs (315 kg)
Dimensions: L x W x H 35.9 x 22.3 x 23.4 in 40.7 x 22.3 x 23.4 in 40.7 x 22.3 x 23.4 in
(911 x 566 x 593 mm) (1033 x 566 x 593 mm) (1033 x 566 x 593 mm)
* - 24 volts optional

32 Redistribution or publication of this document

by any means, is strictly prohibited.
 MDKBD MDKBE MDKBF
ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.
Alternator Cooling Air Flow: 60 Hz 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min)
50 Hz 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min)
FUEL CONSUMPTION:
60 Hz: Full Load 1.3 gph (4.9 liter/hr) 1.9 gph (7.2 liter/hr) 2.5 gph (9.5 liter/hr)
Half Load 0.8 gph (3.0 liter/hr) 1.1 gph (4.2 liter/hr) 1.5 gph (5.7 liter/hr)
50 Hz: Full Load 1.1 gph (4.2 liter/hr) 1.6 gph (6.1 liter/hr) 2.1 gph (8.0 liter/hr)
Half Load 0.7 gph (2.7 liter/hr) 0.9 gph (3.4 liter/hr) 1.3 gph (4.9 liter/hr)
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing
Model V1903B V2203B V2803B
Number of Cylinders 4 4 5
Displacement 113.37 in3 (1857 cm3) 134.07 in3 (2197cm3) 167.57 in3 (2748 cm3)
Bore 3.15 in (80 mm) 3.43 in (87 mm) 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm) 3.64 in (92.4 mm) 3.64 in (92.4 mm)
Compression Ratio 23:1 23:1 23:1
Firing Order (Clockwise Rotation) 1-3-4-2 1-3-4-2 1-3-5-4-2
Fuel Injection Timing 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC 15.5° - 17.5° BTDC

Valve Lash (cold) 0.0071 - 0.0087 in 0.0071 - 0.0087 in 0.0071 - 0.0087 in

(0.18 - 0.22 mm) (0.18 - 0.22 mm) (0.18 - 0.22 mm)
Lube Oil Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 12.7 quart (12 liter)
Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT
Coolant Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 8 quart (7.6 liter)
Coolant Flow Rate: 60 Hz 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min)
50 Hz 10.0 gpm (37.9 liter/min) 10.0 gpm (37.9 liter/min)) 10.0 gpm (37.9 liter/min)
Raw Water Flow Rate: 60 Hz 9.0 gpm (34.1 liter/min) 9.0 gpm (34.1 liter/min) 9.0 gpm (34.1 liter/min)
50 Hz 7.0 gpm (26.5 liter/min) 7.0 gpm (26.5 liter/min) 7.0 gpm (26.5 liter/min)
Combustion Air Flow: 60 Hz 52 cfm (1.45 m3/min) 60 cfm (1.72 m3/min) 41 cfm (1.16 m3/min)
50 Hz 42 cfm (1.21 m3/min) 50 cfm (1.43 m3/min)) 34 cfm (0.96 m3/min)
Heat Rejection to Ambient: 60 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
50 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
CONNECTIONS:
Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)
Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female
Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female
Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)
Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
KEEL COOLING AND DRY EXHAUST:
Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)
Heat Rejection to Coolant: 60 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
50 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
Dry Exhaust Outlet 1-1/2 NPT 1-1/2 NPT 1-1/2 NPT
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts* 12 volts*
Min CCA Rating - SAE @ 32° F (0° C) 500 amps 625 amps 625 amps
Battery Charging 5 amps 5 amps 5 amps
SIZE, WEIGHT, NOISE:
Without Enclosure
Dry Weight 830 lbs (377 kg) 870 lbs (375 kg) 1090 lbs (494 kg)
Dimensions: L x W x H 44.4 x 23.7 x 26.1 in 44.4 x 23.7 x 26.1 in 53.5 x 23.7 x 28.8 in
(1127 x 602 x 663 mm) (1127 x 602 x 663 mm) (1358 x 602 x 732 mm)
With Enclosure
Noise 67/64 dB(A) @ 60/50 HZ 67/64 dB(A) @ 60/50 HZ 67/66 dB(A) @ 60/50 HZ
Dry Weight 890 lbs (404 kg) 930 lbs (422 kg) 1175 lbs (533 kg)
Dimensions: L x W x H 44.4 x 23.7 x 27.5 in 44.4 x 23.7 x 27.5 in 53.5 x 23.7 x 30.0 in
(1127 x 602 x 698 mm) (1127 x 602 x 698 mm) (1358 x 602 x 763 mm)
* - 24 volts optional

33 Redistribution or publication of this document

by any means, is strictly prohibited.
Emissions
The label which states compliance with applicable
EPA and California emissions regulations is located
on the flywheel housing (Figure 14).
California users of this genset should be aware that
unauthorized modifications or replacement of fuel,
exhaust, air intake, or speed control system compo-
nents that affect engine emissions are prohibited.
Unauthorized modification, removal or replacement
of the engine label is prohibited.
You should carefully review Operator (Owner),
Installation and other manuals and information you
receive with your genset. If you are unsure that the
installation, use, maintenance or service of your
genset is authorized, you should seek assistance
from an approved Onan dealer. FIGURE 14. EMISSIONS LABEL

California genset users may use Table 4 as an aid in

locating information related to the California Air Re-
sources Board requirements for emissions control.

TABLE 4. EMISSIONS CONTROL INFORMATION

The California emissions control warranty statement is located in

Emissions Warranty Information the same packet of information as this manual when the genset is
shipped from the factory.
The engine is certified to operate on diesel fuel. See FUEL REC-
Engine Fuel Requirements
OMMENDATIONS (Page 5).
Engine Lubricating Oil Requirements See ENGINE OIL RECOMMENDATIONS (Page 5).
High Idle Speed. This is a service procedure requiring trained
Engine Adjustments
personnel and proper tools. See the Service Manual.
The engine emission control system consists of engine design
Engine Emission Control System
and precision manufacture. (IFI)

34 Redistribution or publication of this document

by any means, is strictly prohibited.
How to Obtain Service
When you need service, parts, or product literature 4:00 PM, Central Standard Time, Monday through
(such as the Service Manual) for your genset, con- Friday, or fax 1-763-528-7229.
tact the nearest authorized distributor. Onan has
factory-trained representatives to handle your Before calling for service, have the following infor-
needs for genset parts and service. mation available:
Call 1-800-888-ONAN to contact the nearest Cum- 1. The complete genset model number and serial
mins/Onan or Onan-only distributor in the United number. See Model Identification (Page 4).
States or Canada. (This automated service utilizes
2. The date of purchase.
touch-tone phones only). Select OPTION 1
(press 1) to be automatically connected to the dis- 3. The nature of the problem. See Troubleshoot-
tributor nearest to you. ing (Page 25).

If you are unable to contact a distributor using the If you have difficulty in arranging service or resolv-
automated service, consult the Yellow Pages. Typi- ing a problem, please contact the Service Manager
cally, our distributors are listed under: at the nearest Cummins/Onan distributor for assis-
tance.
GENERATORS - ELECTRIC,
ENGINES - GASOLINE OR DIESEL, or
RECREATIONAL VEHICLES - EQUIPMENT, WARNING Improper service or replacement of
PARTS AND SERVICE. parts can result in severe personal injury, death,
and/or equipment damage. Service personnel
If you are outside North America, call Onan Corpo- must be trained and experienced in performing
ration at 1-763-574-5000 from 7:30 AM to electrical and/or mechanical service.

35 Redistribution or publication of this document

by any means, is strictly prohibited.
Maintenance Record
Record all periodic and unscheduled maintenance and service. See Periodic Maintenance (Page 12).

HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING

Record the name, address, and phone number of your authorized Onan service center.

36 Redistribution or publication of this document

by any means, is strictly prohibited.
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.