Onan MDKBH Series User manual

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MDKBH
981-0542
11-05
Service Manual
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by any means, is strictly prohibited.

California
Proposition 65 Warning
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to the State of California to cause cancer, birth defects, and
other reproductive harm.
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i
Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS iv. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Identification 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emissions Label 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. CONTROL PANELS 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Control Panel 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Panels 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Display 2-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. OPERATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Extinguisher Port 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Start Checks 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Fuel System 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Genset 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Genset 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Genset 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No-Load Operation 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to Shore Power 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Line Circuit Breakers 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Temperature Operation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Care of New or Re-Built Engine 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ii
SECTION PAGE
4. PERIODIC MAINTENANCE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Periodic Maintenance Schedule 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Inspection 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections 4-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Filter 4-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining/Replacing the Fuel Filter 4-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Engine Cooling System 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. ENCLOSURE, DRIP PAN AND MOUNTING SYSTEM 5-1. . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure Panels 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drip Pan and Mounting System 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. ENGINE AND ACCESSORIES 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Engine Service 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intake Resonator Assembly 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 6-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plugs 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Actuator 6-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. GENERATOR DRIVE 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting Drive and Bearings 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. GENERATOR 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing the Generator 8-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Servicing Brushes and Slip Rings 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Field Flash 8-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Generator Windings 8-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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iii
SECTION PAGE
9. GENSET CONTROL 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Controller 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Remote Digital Display 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local/Remote Control Switch (S4) 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop Switch (CB1) 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hour Meter (M11) 9-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure Sender (E1) 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sender (E2) 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging Regulator (A1) 9-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Exhaust Temperature Switch (S5) 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raw Water Flow Switch (S6) 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug Relay (K3) 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Relay (K4) 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Actuator (A12) 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Isolation Relay (K9) 9-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Interface Module (NIM) 9-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. RECONFIGURING VOLTAGE AND FREQUENCY 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . .
“As Manufactured” Block on Nameplate 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnection Label 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Frequency 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnecting Generator 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Voltage Using Control Switch 10-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Voltage Using Optional Digital Display 10-2. . . . . . . . . . . . . . . . . . . . . . . . . .
11. TROUBLESHOOTING 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with Digital Display 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with Status Lamp 11-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12. SPECIFICATIONS 12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERATOR CONNECTION DIAGRAM A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL WIRING HARNESS A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Redistribution or publication of this document, 
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iv
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL
before operating the genset. Safe operation and
top performance can only be obtained when
equipment is operated and maintained proper-
ly.
The following symbols in this manual alert you to
potential hazards to the operator, service person
and equipment.
DANGER alerts you to an immediate hazard
that will result in severe personal injury or
death.
WARNING alerts you to a hazard or unsafe
practice that can result in severe personal inju-
ry or death.
CAUTION alerts you to a hazard or unsafe
practice that can result in personal injury or
equipment damage.
Electricity, fuel, exhaust, moving parts and batter-
ies present hazards which can result in severe per-
sonal injury or death.
GENERAL PRECAUTIONS
•Keep children away from the genset.
•Do not use evaporative starting fluids. They
are highly explosive.
•Do not step on the genset when entering or
leaving the generator room. Parts can bend or
break leading to electrical shorts or to fuel,
coolant or exhaust leaks.
•To prevent accidental or remote starting while
working on the genset, disconnect the nega-
tive (–) battery cable at the battery.
•Let the engine cool down before removing the
coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray
and cause severe burns.
•Keep the genset, drip pan and compartment
clean. Oily rags can catch fire. Gear stowed in
the compartment can restrict cooling.
•Make sure all fasteners are secure and proper-
ly torqued.
•Do not work on the genset when mentally or
physically fatigued or after having consumed
alcohol or drugs.
•You must be trained and experienced to make
adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
vere personal injury or death.
•Used engine oil has been identified by some
U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
inhale, or contact used oil or its vapors.
•Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
dance with local environmental regulations.
•Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus-
tible materials such as wood and cloth; Class B
fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
•Genset installation and operation must comply
with all applicable local, state and federal
codes and regulations.
GENERATOR VOLTAGE IS DEADLY
•Generator electrical output connections must
be made by a trained and experienced electri-
cian in accordance with applicable codes.
•The genset must not be connected to shore
power or to any other source of electrical pow-
er. Back-feed to shore power can cause elec-
tric shock resulting in severe personal injury or
death and damage to equipment. An approved
switching device must be used to prevent inter-
connections.
•Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth-
ing and shoes are dry, stand on a dry wooden
platform or rubber insulating mat and use tools
with insulated handles.
ENGINE EXHAUST IS DEADLY
•Never sleep in the boat while the genset is run-
ning unless the boat is equipped with properly
working carbon monoxide detectors.
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v
•The exhaust system must be installed in accor-
dance with the genset Installation Manual and
be free of leaks.
•Make sure the bilge is adequately ventilated
with a power exhauster.
•Inspect for exhaust leaks every startup and af-
ter every eight hours of operation.
•For more information about carbon monoxide
see American Boat and Yacht Council (ABYC)
publication TH-22—Educational Information
About Carbon Monoxide.
DIESEL FUEL IS COMBUSTIBLE
•Do not smoke or turn electrical switches ON or
OFF where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equip-
ment. Keep flames, sparks, pilot lights, arc-
producing equipment and all other sources of
ignition well away.
•Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
GASOLINE IS FLAMMABLE AND
EXPLOSIVE
•Because this genset is an Ignition Protected
device, no substitutes are permitted for the
parts listed in the Critical Parts Index of the
genset Parts Catalog. They must be pur-
chased from Onan and be installed in accor-
dance with the genset Service Manual by
those who are trained and experienced in ma-
rine genset service.
BATTERY GAS IS EXPLOSIVE
•Wear safety glasses.
•Do not smoke.
•To reduce arcing when disconnecting or recon-
necting battery cables, always disconnect the
negative (–) battery cable first and reconnect
it last.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•Do not wear loose clothing or jewelry near
moving parts such as PTO shafts, fans, belts
and pulleys.
•Keep hands away from moving parts.
•Keep guards in place over fans, belts, pulleys,
and other moving parts.
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. Do not operate a diesel-powered genset
where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and
operators of the genset are solely responsible for
operating the genset safely.
POST THESE SAFETY PRECAUTIONS IN POTENTIAL
HAZARD AREAS OF THE BOAT
M-11
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by any means, is strictly prohibited.

Redistribution or publication of this document, 
by any means, is strictly prohibited.

1-1
1. Introduction
ABOUT THIS MANUAL
This is the Service 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 it at top perfor-
mance. The owner is responsible for performing
maintenance in accordance with the PERIODIC
MAINTENANCE SCHEDULE (p. 4-1). This manual
also includes genset specifications, information on
how to obtain service, and information regarding
compliance with emissions regulations.
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 personal injury or death. A per-
sonal attendant, redundant power or alarm sys-
tem must be used if genset operation is critical.
See the Parts Manual for part identification numbers
and required quantities. Genuine Onanreplace-
ment parts are recommended for best results.
WARNING Because this genset is an Ignition
Protected Device, no substitutes are permitted
for the parts listed in the Critical Parts Index of
the genset Parts Catalog. They must be pur-
chased from Onan and be installed in accor-
dance with the genset Service Manual by those
who are trained and experienced in marine gen-
set service.
WARNING Improper service or replacement of
parts can lead to severe personal injury or death
and to damage to equipment and property. Ser-
vice personnel must be qualified to perform
electrical and mechanical service.
MODEL IDENTIFICATION
Be ready to provide the genset model and serial
numbers on the nameplate when contacting Onan
for parts, service and product information. Fig-
ure 1-1 illustrates the nameplate and its location on
the side of the control box.
FIGURE 1-1. TYPICAL NAMEPLATE
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by any means, is strictly prohibited.

1-2
EMISSIONS LABEL
The engine has a label on the air intake (Figure 1-2)
which states compliance with applicable EPA and
California emissions regulations.
California users of this genset should be aware that
unauthorized modifications or replacement of fuel,
exhaust, air intake, or speed control system compo-
nents that affect engine emissions are prohibited.
Unauthorized modification, removal or replacement
of the engine label is prohibited.
You should carefully review Operator (Owner),
Installation and other manuals and information you
received with your genset. If you are unsure that the
installation, use, maintenance or service of your
genset is authorized, you should seek assistance
from an approved Onan dealer.
California genset users may use Table 1-1 as an aid
in locating information about the California Air Re-
sources Board requirements for emissions control.
ENGINE
EMISSIONS
LABEL
FIGURE 1-2. EMISSIONS LABEL
TABLE 1-1. EMISSIONS CONTROL INFORMATION
Emissions Warranty Information The California emissions control warranty statement is located in the same packet of
information as this manual when the genset is shipped from the factory.
Engine Fuel Requirements The engine is certified to operate on diesel fuel. See FUEL RECOMMENDATIONS
(p. 3-1).
Engine Lubricating Oil Require-
ments See ENGINE OIL RECOMMENDATIONS (p. 3-1).
Engine Adjustments High Idle Speed. This is a service procedure requiring trained personnel and proper
tools. See the Service Manual.
Engine Emission Control Sys-
tem
The engine emission control system consists of engine design and precision
manufacture. (IFI)
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2-1
2. Control Panels
LOCAL CONTROL PANEL
Refer to Figure 2-1.
Control Switch
Starting: Push and Hold START to preheat, crank
and start the genset. The green status lamp comes
on when the genset is running. (Preheat is the peri-
od of time prior to engine cranking when the glow
plugs preheat the combustion chambers. The time
is automatically varied by the genset controller on
the basis of engine temperature.)
Stopping: Push and Release STOP (Prime) to
stop the genset.
Priming: Push and Hold STOP (Prime to prime the
fuel system (amber lamp comes on in 2 seconds to
indicate priming).
Status Lamps
The control switch has two status lamps. The amber
status lamp comes on during priming, blinks rapidly
during cranking and goes out when the engine is up
to speed. If the genset shuts down abnormally, this
lamp will slowly blink a numerical code to indicate
the cause of shutdown. See Troubleshooting (Sec-
tion 11). The green status lamp comes on to indi-
cate that the genset is running.
Emergency Stop Switch
In an emergency push the switch to OFF. Push it to
ON after all necessary repairs to the genset and
connected equipment have been made.
Line Circuit Breaker
The line circuit breaker protects the AC power leads
connected to the genset from overloads and equip-
ment short circuits.
Hour Meter
The hour meter records genset operating time in
hours. It cannot be reset.
REMOTE CONTROL PANELS
Remote Control
The boat may be equipped with several remote con-
trol stations having e-Series Digital Displays
(p. 2-2) or control switches with status lamps.
Boat Monitoring System
The boat may be equipped to monitor genset opera-
tion on an integrated monitoring system using an
SAE J1939 or SmartCraftnetwork protocol.
OIL FILL NECK
LINE CIRCUIT BREAKER
CONTROL SWITCH &
STATUS INDICATOR LAMPS
EMERGENCY
STOP SWITCH
HOUR METER
FIGURE 2-1. LOCAL CONTROL PANEL
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2-2
DIGITAL DISPLAY
The e-Series Digital Display has an LCD screen
with 4 navigation buttons, 3 status lamps, a START
button and a STOP button (Figure 2-2).
Turning On the Display
Touch any button to turn on the Display, which will
initialize and attempt to establish communications
with the genset controller. All connected Displays
will turn on automatically when the genset is started
at any station. They will all turn off 5 minutes after
the genset has received a normal command to stop.
They will stay on indefinitely until a fault shutdown is
cleared by touching any button on any Display.
Start Button
Starting the Genset: Push and Hold START until
the genset starts. The GENSET status lamp blinks
while the engine is cranking. It comes on when the
genset starts and stays on while it runs. The status
displayed on the LCD changes from Starting to Run-
ning (Figure 2-3). See STARTING THE GENSET
(p. 3-3).
Stop Button
Stopping the Genset: Push and Release STOP.
The GENSET status lamp will go out. The status
displayed on the LCD will change from Running to
Stopped (Figure 2-3). See STOPPING THE GEN-
SET (p. 3-3).
Priming the Fuel System: Push and Hold STOP.
The GENSET status lamp will blink. The status dis-
played on the LCD will change to Priming in 2 sec-
onds (Figure 2-3). See PRIMING THE FUEL SYS-
TEM (p. 3-3).
Genset Status Lamps
GENSET – This status lamp (green) blinks while the
engine is cranking or the fuel system is being
primed. It stays on while the genset is running.
PRE-ALARM – This status lamp (amber) comes on
when an engine Pre-Alarm condition exists
(p. 2-5). It blinks rapidly while the genset is running
in voltage adjust mode (p. 10-1).
ALARM – This status lamp (red) blinks during fault
shutdown (p. 2-4).
FIGURE 2-2. DIGITAL DISPLAY
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2-3
Genset Status Screens
Genset status is displayed on 3 screen pages (Fig-
ure 2-3). GEN STATUS PG1 appears when the Dis-
play is turned on. Press the double arrows [ ] to
toggle between the 3 screen pages.
The Status line on PG1 will display the word Prim-
ing, Starting, Running, Stopped or Volt Adj. The rest
of the lines on the 3 status screen pages display AC
output voltage, AC frequency, engine coolant tem-
perature, engine oil pressure, starting battery volt-
age and total genset running time.
Note: The total time on the control panel hour meter
(Page 2-1) prevails if the total time on the e-Series
Digital Display is different. See Configuring Replace-
ment Genset Controller (p. 2-7) to reset the Digital
Display to match the control panel hour meter.
TO
FIG. 2-7
TO
FIG. 2-5
TO
FIG. 2-8
FIGURE 2-3. TYPICAL GENSET STATUS SCREENS
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2-4
Fault Screens
If a fault shutdown occurs the ALARM status lamp
will blink and the LCD screen will display the Fault
Number, a description of the Fault and the hour in
total genset running time when the Fault occurred
(Figure 2-4). Refer to TABLE 11-1. TROUBLE-
SHOOTING GENSET FAULTS to diagnose and
correct the problem.
The e-Series Digital Display will display the fault in-
definitely. Touch any button to clear the fault. The
display will turn off in 5 minutes after the fault has
been cleared.
Press [ BACK] to go back to the GEN STATUS
screen.
FIGURE 2-4. TYPICAL FAULT SCREEN
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2-5
Displaying Last 5 Faults
To display any of the last five faults, press the FAULT
button on any GEN STATUS screen. Then press the
HIST button on the FAULT screen (Figure 2-5).
The FAULT HISTORY screen will display the last
Fault Number, a description of the Fault and the
hour in total genset running time when the fault oc-
curred. Press the double arrows [ ] to toggle be-
tween the last 5 faults. If there are no faults, the
FAULT HISTORY screen will display No Stored
Faults.
Press [ BACK] to go back to GEN STATUS.
Engine Pre-Alarm Screens
The PRE-ALARM status lamp will start to blink
when engine oil pressure or temperature ap-
proaches its limit for engine shutdown. The Display
will display Low Oil Pressure or High Engine Tem-
perature on the PRE-ALARM screen (Figure 2-6).
Press [ BACK] to go back to GEN STATUS to moni-
tor the engine temperature or oil pressure.
Service the genset as required.
OR
FROM FAULT,
FIG. 2-3
FIGURE 2-5. FAULT HISTORY
FROM FAULT,
FIG. 2-3
OR
FIGURE 2-6. ENGINE PRE-ALARMS
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2-6
Screen Brightness and Contrast
To adjust the brightness and contrast of the LCD
screen and status lamps, go to the SCREEN AD-
JUST screen by pressing SCREEN on any GEN
STATUS screen. Press NEXT to select Brightness
or Contrast. Increase or decrease the selected item
by pressing the increase-decrease buttons [ ].
See Figure 2-7. (“Contrast” applies only to the LCD
screen.)
Press [ BACK] to save the settings and go back to
GEN STATUS.
Display Setup
Go to the SETUP screen by pressing SETUP on any
GEN STATUS screen. Press the up-down arrows
[] to select Display Setup and press ENTER.
See Figure 2-8.
Units: To change the units of measure on the GEN
STATUS screens, press NEXT to select Units. Then
press the up-down arrows [ ] to toggle between
Metric and SAE units.
Press [ BACK] to save the selection and go back to
GEN STATUS.
AC Voltmeter Calibration: To calibrate the Display
Voltmeter, press NEXT to select AC Voltmeter
Calibration. Then press the up-down arrows [ ]
to increase or decrease the voltage displayed to
correspond to an accurate AC output voltmeter
(line-to-line or line-to-neutral, as desired).
Press [ BACK] to save the selection and go back to
GEN STATUS.
Note: This procedure does not change AC output
voltage. See Adjusting AC Output Voltage (Sec-
tion 10).
Genset and Display Information
Go to the SETUP screen by pressing SETUP on any
GEN STATUS screen. Press the up-down arrows
[] to select Genset Info or Display Info and press
ENTER. See Figure 2-8. This information may be
requested by the service technician.
Keep pressing [ BACK] to get back to GEN STA-
TUS.
FROM SCREEN,
FIG. 2-3
FIGURE 2-7. SCREEN BRIGHTNESS & CONTRAST
FROM SETUP,
FIG. 2-3
FIGURE 2-8. SETUP, GENSET & DISPLAY INFO
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2-7
Configuring Genset Controller Using
Digital Display
A replacement controller must be configured to
match the genset. See shutdown due to INVALID
GENSET CONFIGURATION—CODE NO. 37
(p. 11-12). Also, the Digital Display hour meter
should be reset to match the control panel hour me-
ter (p. 2-1).
Setting Configuration: Stop the genset and then
press STOP 6 times to display the configuration
screen (Figure 2-9). Press NEXT to select Genset
Config. Press the up-down arrows [ ], as neces-
sary, to increase or decrease the code number. The
configuration code number for this genset is “19.”
Press [ BACK] to save the selection and get back to
GEN STATUS.
Resetting Digital Display Hour Meter: Press
NEXT to select Set Hour Meter. Then press the up-
down arrows [ ] to match the number of hours on
the control panel hour meter (p. 2-1).
Press [ BACK] to save the selection and get back to
GEN STATUS.
Configuring Genset Controller Using
Control Switch
Remove the insulating connectors from wiring har-
ness connectors CONFIG 1 and CONFIG 2 in the
control box and connect them together. This places
the control in configuration mode. (In configuration
mode the control will not start, prime or display
faults.)
In configuration mode the status lamp on the control
switch will blink the numeric configuration code, a
two-digit number. Each time START is pressed the
number will increase one unit. Each time STOP is
pressed the number will decrease one unit. Press
START or STOP, as necessary, to increase or de-
crease the code number. The configuration code
number for this genset is “19.” The lamp should blink
as follows when configured correctly:
blink — pause — blink-blink-blink-blink-blink-
blink-blink-blink-blink — long pause — repeat
When configured properly, disconnect CONFIG 1
from CONFIG 2 and re-install the insulating connec-
tors that were removed from each connector.
FIGURE 2-9. CONFIGURING CONTROLLER AND
SETTING HOUR METER
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3-1
3. Operation
FUEL
WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multi-
class ABC fire extinguisher handy.
High quality Grade 2-D diesel fuel is necessary for
good performance and long engine life. Diesel fuels
specified by EN 590 or ASTM D975 are recom-
mended. Use Grade 1-D diesel fuel if the fuel tank is
exposed to temperatures below 40°F (5°C).
The Cetane number should not be less than 45 and
sulfur content not more than 0.5 percent (by weight).
Where fuel is exposed to cold ambient tempera-
tures, use fuel that has a cloud point (temperature at
which wax crystals begin to form) at least 10°F
(6°C) degrees below the lowest expected fuel tem-
perature.
Fuel lubricity should pass a minimum load level of
3100 grams as measured by ASTM D6078 or maxi-
mum scar diameter of 0.45 mm as measured by
ASTM D6079 or ISO 12156-1.
ENGINE OIL
Use API (American Petroleum Institute) Service
Category CI-4 engine oil or better. Also look for the
SAE (Society of Automotive Engineers) viscosity
grade. Referring to Figure 3-1, choose the viscosity
grade appropriate for the ambient temperatures ex-
pected until the next scheduled oil change. Multi-
grade oils such as SAE 15W-40 are recommended
for year-round use.
FIGURE 3-1. OIL VISCOSITY GRADE VS. AMBIENT
TEMPERATURE
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