Onan MDKBK User manual

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Preliminary
MDKBK MDKBL MDKBM MDKBN
MDKBP MDKBR MDKBS
MDKBT MDKBU
981-0543C
01-07
Service Manual
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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.
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by any means, is strictly prohibited.

i
Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS v. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model Identification 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. CONTROL PANEL 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control and Monitoring 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Local Control Panel 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Display 2-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. OPERATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Batteries 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Extinguisher Port 3-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Start Checks 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming the Fuel System 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting the Genset 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Genset 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop 3-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading the Genset 3-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
No-Load Operation 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting Line Circuit Breakers 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connecting to Shore Power 3-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Temperature Operation 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Care of New or Re-Built Engine 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exercising the Genset 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storing the Genset 3-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ii
SECTION PAGE
4. PERIODIC MAINTENANCE 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Inspection 4-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Battery and Battery Connections 4-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Engine Oil Level 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil and Filter 4-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Draining/Replacing Fuel Filters 4-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintaining the Engine Cooling System 4-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. GENSET CONTROL 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Controller 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Digital Display 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Switch (S4) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergency Stop Switch (CB1) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DC Circuit Breaker (CB2) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Master Hour Meter (M11) 5-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Oil Pressure Sender (E1) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Coolant Temperature Sender (E2) 5-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raw Water Flow Switch (S6) 5-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Exhaust Temperature Switch (S5) 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Coolant Level Switch (S3) 5-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Actuator (A12) 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plug Relay (K3) 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter Relay (K4) 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Isolation Relay (K9) 5-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Network Interface Module (NIM) 5-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bonding For Electrostatic Discharge Control 5-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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iii
SECTION PAGE
6. ENGINE AND ACCESSORIES 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Major Engine Service 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Sensors 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Governor Actuator 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Manifold 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel System 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Glow Plugs 6-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starter 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ground Isolation Relay K9 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Charging Alternator 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raw Water Pump 6-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. GENERATOR 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing Generator 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disassembly 7-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnecting the Generator 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Circuit Breakers 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Change Frequency 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Adjust Voltage 7-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8. RECONFIGURING VOLTAGE AND FREQUENCY 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . .
As Manufactured 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnection Label 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing Frequency 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reconnecting Generator 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Voltage Using Optional Digital Display 8-2. . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Voltage Using Control Switch 8-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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iv
SECTION PAGE
9. TROUBLESHOOTING 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with Digital Display 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting with Status Lamp 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. SPECIFICATIONS 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (SHEET 1) A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (SHEET 2) A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (SHEET 3) A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL WIRING HARNESS—MODELS MDKBK, MDKBL, MDKBM, MDKBN A-4. . . .
CONTROL WIRING HARNESS—MODELS MDKBP, MDKBR, MDKBS A-5. . . . . . . . . . . . .
CONTROL WIRING HARNESS—MODELS MDKBT, MDKBU A-6. . . . . . . . . . . . . . . . . . . . .
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v
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.
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.
•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.
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.
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.
MOVING PARTS CAN CAUSE SEVERE
PERSONAL INJURY OR DEATH
•Do not wear loose clothing or jewelry near
moving parts such as PTO shafts, fans, belts
and pulleys.
•Keep hands away from moving parts.
•Keep guards in place over fans, belts, pulleys,
and other moving parts.
BATTERY GAS IS EXPLOSIVE
•Wear safety glasses.
•Do not smoke.
•To reduce arcing when disconnecting or recon-
necting battery cables, always disconnect the
negative (−) battery cable first and reconnect
it last.
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vi
FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
Flammable vapor can cause a diesel engine to
overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury and
death. Do not operate a diesel-powered genset
where a flammable vapor environment can be
created by fuel spill, leak, etc. The owners and
operators of the genset are solely responsible for
operating the genset safely.
GENERAL PRECAUTIONS
•Keep children away from the genset.
•Do not use evaporative starting fluids. They
are highly explosive.
•Do not step on the genset when entering or
leaving the generator room. Parts can bend or
break leading to electrical shorts or to fuel,
coolant or exhaust leaks.
•To prevent accidental or remote starting while
working on the genset, disconnect the 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 coolant, is tox-
ic to humans and animals. Clean up spills and
dispose of used engine coolant in accordance
with local environmental regulations.
•Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary 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.
POST THESE SAFETY PRECAUTIONS IN POTENTIAL
HAZARD AREAS OF THE BOAT
M-10
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1-1
1. Introduction
ABOUT THIS MANUAL
This is the Service Manual for the generator sets
(gensets) listed on the front cover.
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.
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.
See the Parts Manual for part identification numbers
and required quantities. Genuine Onan®replace-
ment parts are recommended for best results.
MODEL IDENTIFICATION
Be ready to provide the genset model and serial
numbers on the nameplate when contacting Onan
for parts, service and product information. Fig-
ure 1-1 illustrates the nameplate and its location on
the side of the control box. Every character in these
numbers is significant. (The last character of the
model number is the specification letter, which is im-
portant for obtaining the right parts.)
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.
FIGURE 1-1. TYPICAL NAMEPLATE
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1
This side is intentionally blank
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by any means, is strictly prohibited.

2-1
2. Control Panel
REMOTE CONTROL AND MONITORING
Remote e-Series Digital Displays and
Control Switches
The boat may be equipped with several remote gen-
set control stations having either an e-Series Digital
Display or control switch.
Boat Monitoring System
The boat may also be equipped to monitor genset
operation on an integrated monitoring system using
an SAE J1939 or SmartCraft™network protocol.
See NETWORK INTERFACE MODULE (NIM) on
Page 5-10.
LOCAL CONTROL PANEL
Refer to Figure 2-1.
Control Switch Panel (Standard)
Control Switch: This switch is used to start and
stop the genset and prime fuel.
•Push and Hold START to preheat, crank and
start the genset. The green lamp comes on
when the genset is running. (Preheat is the pe-
riod of time prior to engine cranking when the
glow plugs preheat the combustion chambers.
The time is automatically varied by the genset
controller on the basis of engine temperature.)
•Push and Release STOP (Prime) to stop the
genset.
•Push and Hold STOP (Prime) to prime the fuel
system (amber lamp comes on in 2 seconds to
indicate priming).
Status Lamps: The control switch has two status
lamps. The amber status lamp comes on during
priming, blinks rapidly during cranking and goes out
when the engine is up to speed. If the genset shuts
down abnormally, this lamp will slowly blink a nu-
merical code to indicate the cause of shutdown. See
Troubleshooting (Section 9). The green status lamp
comes on to indicate that the genset is running.
Emergency Stop Switch: In an emergency push
the switch to OFF. Push it to ON after all necessary
repairs to the genset and connected equipment
have been made.
DC Circuit Breaker: This circuit breaker protects
the DC control circuits of the genset from short cir-
cuits. Reset after all necessary repairs have been
made to the genset.
Hour Meter: The hour meter records genset operat-
ing time in hours. It cannot be reset.
e-Series Digital Display Panel (Optional)
The control panel may have an e-Series Digital Dis-
play instead of a control switch. See Page 2-3 for
details.
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2-2
DC CIRCUIT
BREAKER
EMERGENCY
STOP SWITCH
EMERGENCY
STOP SWITCH
DC CIRCUIT
BREAKER
DIGITAL DISPLAY
CONTROL SWITCH
WITH STATUS LAMPS
HOUR
METER
OPTIONAL DIGITAL
DISPLAY PANEL
STANDARD CONTROL
SWITCH PANEL
FIGURE 2-1. GENSET CONTROL PANEL
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2-3
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 establish communications with the
genset controller. All connected Displays will turn on
automatically when the genset is started at any sta-
tion. They will all turn off 5 minutes after the genset
has received a normal command to stop. If a fault
occurs, they will stay on until the fault 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 preheating and cranking. It
comes on when the genset starts and stays on while
it runs. The status displayed on the LCD changes
from Starting to Running (Figure 2-3). See START-
ING 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. 2-6). It blinks rapidly while the genset is running
in voltage adjust mode (p. 8-1).
ALARM −This status lamp (red) blinks during fault
shutdown (p. 2-5).
FIGURE 2-2. DIGITAL DISPLAY
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2-4
Genset Status
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
temperature, engine oil pressure, starting battery
voltage and total genset running time.
Note:The total time on the master hour meter (p. 5-5)
prevails if the total time on the e-Series Digital Dis-
play is different. See Configuring Replacement Gen-
set Controller (p. 2-8) to reset the Digital Display to
match the master 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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2-5
Fault Screen
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 9-1. 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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2-6
Fault History
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-Alarms
The PRE-ALARM status lamp will come on when
engine oil pressure or temperature approaches its
limit for engine shutdown. The Display will display
Low Oil Pressure or High Engine Temperature 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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2-7
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 8).
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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2-8
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. 9-11). Also, the Digital Display hour meter
should be reset to match the master hour meter
(p. 5-5).
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 is marked on the genset
nameplate. Also see Table 2-1.
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 master hour meter (p. 5-5).
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. For example, the lamp
should blink as follows when configured for a
1-Phase, Model MDKBR genset (15):
blink — pause — blink-blink-blink-blink-blink —
long pause — repeat code
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
TABLE 2-1. GENSET CONFIGURATION CODES
GENSET MODEL CODE NUMBER
MDKBK—1-Phase 18
MDKBL—1-Phase 18
MDKBM—1-Phase 12
MDKBN—1-Phase 13
MDKBP—1-Phase 14
MDKBP—3-Phase 24
MDKBR—1-Phase 15
MDKBR—3-Phase 16
MDKBS—1-Phase 17
MDKBS—3-Phase 25
MDKBT—1-Phase 41
MDKBT—3-Phase 43
MDKBU—1-Phase 42
MDKBU—3-Phase 45
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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.
Note:Ultra Low Sulfur Diesel (ULSD) fuel that meets
the ASTM D975 standard for lubricity is suitable for
use with this engine. The 1 to 2 percent less energy
content of the fuel can have a slight effect on maxi-
mum engine power.
Note:B5 Bio-Diesel fuel that meets industry specifi-
cations and quality is suitable for use with this en-
gine.
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
ENGINE COOLANT
Use the best quality ethylene glycol antifreeze solu-
tion available. It should be fully formulated with rust
inhibitors and coolant stabilizers. A 50/50 mixture of
water and ethylene glycol is recommended to pro-
vide protection from freezing down to -34°F
(-37°C).
Use fresh water that is low in minerals and corrosive
chemicals for the coolant mixture. Distilled water is
best.
See Specifications (Section 10) regarding coolant
capacity.
WARNING Ethylene Glycol antifreeze is con-
sidered toxic. Dispose of it according to local
regulations for hazardous substances.
BATTERIES
Reliable genset starting and starter service life de-
pend upon adequate battery system capacity and
maintenance. See MAINTAINING THE BATTERY
AND BATTERY CONNECTIONS (p. 4-2) and
Specifications (Section 10).
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