Onan MDKBH Series Service Manual Download Page 4

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Table of Contents

SECTION

PAGE

SAFETY PRECAUTIONS

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1. INTRODUCTION

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About this Manual

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Model Identification

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Emissions Label

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2. CONTROL PANELS

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Local Control Panel

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Remote Control Panels

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Digital Display

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3. OPERATION

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Fuel

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Engine Oil

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Engine Coolant

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Batteries

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Fire Extinguisher Port

3-2

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Pre-Start Checks

3-3

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Priming the Fuel System

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Starting the Genset

3-3

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Stopping the Genset

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Emergency Stop

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Loading the Genset

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No-Load Operation

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Connecting to Shore Power

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Resetting Line Circuit Breakers

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Cold Temperature Operation

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Care of New or Re-Built Engine

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Exercising the Genset

3-5

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Storing the Genset

3-5

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Redistribution or publication of this document,

by any means, is strictly prohibited.

Summary of Contents for MDKBH Series

Page 1: ...Caution This document contains mixed page sizes 8 5 x 11 or 11 x 17 which may affect printing Please adjust your printer settings according to the size of each page you wish to print...

Page 2: ...MDKBH 981 0542 11 05 Service Manual Redistribution or publication of this document by any means is strictly prohibited...

Page 3: ...ng 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 a...

Page 4: ...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...

Page 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 Governo...

Page 6: ...tuator 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 Frequ...

Page 7: ...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...

Page 8: ...ur 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 no...

Page 9: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 10: ...r 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 resul...

Page 11: ...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 EMISS...

Page 12: ...ec 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 a...

Page 13: ...atus 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...

Page 14: ...y 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 pr...

Page 15: ...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 dis...

Page 16: ...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...

Page 17: ...e 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 th...

Page 18: ...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 configura...

Page 19: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 20: ...nt 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 fue...

Page 21: ...adequate battery system capacity and maintenance See MAINTAINING THE BATTERY AND BATTERY CONNECTIONS p 4 2 and Specifications Section 12 FIRE EXTINGUISHER PORT A genset with an enclosure has a fire e...

Page 22: ...panel 1 Push and Hold START on the e Series Digital Display or control switch until the genset starts The genset status lamp blinks when the engine is cranking and comes on and stays on when the gens...

Page 23: ...emperature ref ISO 3046 Ei ther low barometric pressure high altitude or high ambient temperature will decrease engine power It may be necessary to run fewer loads under such conditions NO LOAD OPERAT...

Page 24: ...moisture re lubricates the engine uses up fuel before it be comes stale and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life STORING...

Page 25: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 26: ...Hrs Every 2 Years Every 5 Years 2000 Hrs Page General Inspection x1 4 2 Check Engine Oil Level x 4 3 Check Battery x2 4 2 Check V Belt Tension x3 4 9 Drain Fuel Filters x 4 5 Check Siphon Break x 4 8...

Page 27: ...enset opera tion Also when a water exhaust separator is pro vided see Installation Manual open the sea cock for the water drain hose Check for and replace hoses that leak or are dam aged Battery Conne...

Page 28: ...ck into the fill neck and seat the plug which snaps into its socket Remove the plug and dipstick again and check the oil level on the dip stick 2 Add or drain oil as necessary See ENGINE OIL RECOMMEND...

Page 29: ...t for connecting a hose fitting to facilitate oil draining If an oil pump out system is installed follow the instructions provided 3 Close the oil drain valve 4 Spin off the old oil filter with a filt...

Page 30: ...ed 1 Disconnect the negative cable at the battery to prevent the engine from starting and close any fuel supply and return valves 2 Open the front access door and drain the filter about 1 2 cup 120 ml...

Page 31: ...NING Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable from the battery to prevent the engine from starting WARNING Hot coolant spray can cause sev...

Page 32: ...UST MANIFOLD COOLANT RESERVOIR EXHAUST WATER MIXER WITH HIGH TEMPERATURE EXHAUST SWITCH COULD BE CONNECTED TO EXTERNAL SIPHON BREAK AT THIS POINT SEE INSTALLATION MANUAL RAW WATER FLOW SENSOR HEAT EXC...

Page 33: ...side of the gasket 4 Replenish any lost coolant secure the pres sure cap secure the access door and recon nect the battery cables negative last Siphon Break WARNING Bypassing a siphon break or failin...

Page 34: ...wrench while loosening the bolt 3 Loosen both bolts so that the pump can pivot 4 Pivot the pump out to tighten belt tension Hold tension by tightening the tension adjusting bolt and check it by applyi...

Page 35: ...ove the front and top access doors If work space is limited remove the end panel Fig ure 4 6 to be able to hold the nut on the pump pivot bolt Figure 4 8 with an open end wrench while loosening the bo...

Page 36: ...TION Do not lubricate the impeller with grease or oil or other petroleum prod ucts because they are known to chemically attack impeller materials 9 Secure the cover and O ring 10 Remount the pump reco...

Page 37: ...s The tubes are made of rela tively soft copper alloy and can be damaged Use thread sealant on the drain plug and a new clean out cover gasket if the old one is torn or other wise damaged Reassemble a...

Page 38: ...Panel This panel is secured by 5 screws along its left edge looking from the back 3 along its right edge and 7 on its back Remove this panel for access to the generator drive Page 7 1 BACK PANEL AIR I...

Page 39: ...panel and remove the two screws that secure the oil fill neck to the control panel This panel assembly can be pulled forward and removed without having to disturb connections in the AC output box AC...

Page 40: ...ISOLATION MOUNT 3 FRONT ENGINE SUPPORT BRACKET RUBBER NOISE PLUGS GENERATOR END BELL SUPPORT BRACKET FIGURE 5 2 DRIP PAN AND MOUNTING SYSTEM Redistribution or publication of this document by any means...

Page 41: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 42: ...oved Page 5 1 Adjusting Valve Lash Do not use the fuel injection timing marks Figure 6 1 when adjusting valve lash Using them could lead to misadjustments Valve lash should be adjusted when both valve...

Page 43: ...sure that The brush block leads are connected Page 8 4 The fuel lines are connected at the fuel injector Figure 6 5 The oil fill hose is connected at the engine fill tube Page 6 5 All adjustments to t...

Page 44: ...ght side panel for access Page 5 1 Use new manifold and mixer gaskets when re assembling Torque the 4 manifold nuts and the 3 mixer bolts to 8 lb ft 11 N m EXHAUST MANIFOLD COOLANT RESERVOIR WATER EXH...

Page 45: ...n er of known volume such as a 1 or 2 liter quart bottle 2 Prime the genset by pushing the Start Stop switch to STOP Prime and holding it there for the duration of the test It should not take longer t...

Page 46: ...er opera tion p 9 7 and replace if necessary Also check for B at relay socket terminal 30 for continuity between terminal 87 and the glow plugs and for continuity between terminal 86 and B ground Clea...

Page 47: ...SUPPLY CLAMP WIRE TIE HOSE FROM PUMP MUST CROSS OVER HOSE TO ENGINE GLOW PLUGS 2 FOR THE QUICK PUMP TEST PINCH HERE TO CUT OFF BYPASS FUEL FLOW FIGURE 6 5 FUEL SYSTEM AND GLOW PLUGS Redistribution or...

Page 48: ...rotor clockwise by hand against the fuel rack return spring It should rotate smoothly about 1 2 inch 12 mm and re turn smoothly A If the governor binds or catches re move the bearing carrier and stato...

Page 49: ...RETURN SPRING TERMINALS SHAFT SNAP ON COVER SPRING SHAFT BEARING ASSEMBLY ROTOR RETAINER RING BASE SPRING LEG MUST CATCH UNDERNEATH FIGURE 6 6 GOVERNOR ACTUATOR Redistribution or publication of this d...

Page 50: ...o keep it in place on the shaft Base See engine Workshop Manual 981 0533 if it is necessary to remove the actuator base or replace internal engine governor parts The stator must be removed for access...

Page 51: ...for access to the speed adjusting screw 4 Disconnect the actuator leads and connect a 12 volt battery to the actuator terminals using a battery switch The battery will hold the gover nor mechanism ag...

Page 52: ...ounting bolts to 29 lb ft 39 N m Make sure start er B is connected to genset B Negative Ground Connection Before installing the starter motor make sure that the engine block is grounded properly depen...

Page 53: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 54: ...to the tapered end of the rotor shaft The pulley must be removed to remove the generator rotor from the engine generator adapter ENGINE GENERATOR ADAPTER ENGINE FLYWHEEL DRIVE PULLEY FLEXIBLE COUPLING...

Page 55: ...break the pulley free of the generator shaft taper To keep the rotor from turn ing while loosening the pulley bolt hold the fan bolt with a wrench Torque the center bolt to 45 lb ft 60 N m when reasse...

Page 56: ...ent to the rotor windings through the brush block assembly The rotor shaft is supported on both ends by sealed ball bearings The drive belt pulley and fan are cen ter bolted to the tapered rotor ends...

Page 57: ...SUPPORT BRACKET FAN SLIP RINGS LEADS GROMMET CLIP NOTE ON SKEWED STATORS STRAIGHT STATOR SHOWN THE THROUGHBOLTS MUST COME THROUGH THE SLOTTED RATHER THAN ROUND HOLES FOR PROPER ALIGNMENT OF END BELL...

Page 58: ...weight to prevent damage to the adapter and bearing Stator Reassembly Reassembly is the reverse of removal Note the fol lowing 1 Loosen the end bell support bracket bolts if not already removed so th...

Page 59: ...rush block assembly if either brush is shorter than 7 16 inch 11 mm binds in the brush block or is damaged in any way Reconnect the field leads F black to the outside terminal and F red to the inside...

Page 60: ...nd B2 from charging regulator AVR1 Figure 9 1 Disconnect Q1 and Q2 from controller A1 by pulling green connector P3 Pins 4 and 5 Open Winding Test Measure resistance across each winding lead pair Tabl...

Page 61: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 62: ...prevent the engine from starting CAUTION Makeshift meter test probes used for testing Control Board connections during troubleshooting can damage pin sockets by spreading or dislodging the contact wip...

Page 63: ...IRCUIT BREAKER CB3 CONTROL SWITCH S4 EMERGENCY SWITCH CB1 HOUR METER M11 CONNECTORS P1 P2 P3 OPTIONAL NIM WITH CONNECTOR HARNESS RELAYS K3 AND K4 FIGURE 9 1 GENSET CONTROLLER AND ITS MOUNTING Redistri...

Page 64: ...ables complete fault detection Stop Touch the control switch to STOP Prime The controller 1 Disables output voltage 2 Deenergizes the fuel lift pump and governor ac tuator 3 Turns off the green run la...

Page 65: ...RS LOW RAW WATER FLOW K4 START ENGINE CUSTOMER CONNECTIONS BATTERY CHARGER CONFIGURATION HZ DC VOLT SELECT Optional BATTERY B DISPLAY START STOP RS485 NIM J1939 OR SMART CRAFT ELECTRIC FUEL PUMP K3 GL...

Page 66: ...erminals 7 and 8 or Amber when battery voltage is applied to terminals 7 and 6 EMERGENCY STOP SWITCH CB1 The switch circuit breaker is mounted on the control panel Figure 9 1 Disconnect the leads and...

Page 67: ...stat housing Figure 9 4 Use thread sealant and engage at least two full threads when installing In isolated ground applications the sender has two terminals Replace the sender if resistance is not app...

Page 68: ...ing into it 1 psi Replace the switch if it does not open and close GLOW PLUG RELAY K3 The glow plug relay is mounted on its wiring socket on the controller mounting bracket Figure 9 1 Pull the relay o...

Page 69: ...ll be cut when the genset is in an SAE J1939 network application The jumper must remain uncut when the genset is in a SmartCraft network application 3 Jumpers W3 and W4 are used to assign the J1939 ne...

Page 70: ...onnectors J5 P6 and P7 p A 1 If application frequency is different from As Manufactured frequency Connect J5 to P6 for 60 HZ Disconnect J5 from P7 for 50 HZ Apply the appropriate reconfiguration label...

Page 71: ...s in voltage adjust mode The line for displaying the voltage is filled in as shown in Figure 10 3 A separate voltmeter is re quired for voltage adjustment 1 Start the genset and let voltage and freque...

Page 72: ...of the last five faults in fault history TROUBLESHOOTING WITH STATUS LAMP If a fault shutdown occurs the amber status lamp on the control switch will repeatedly blink sets of 3 4 5 or 7 blinks One bli...

Page 73: ...onnections recharging or replacing the battery or replacing damaged battery cables p 4 2 4 If there still is no response disconnect the mate to connector J4 P1 or P33 in the control box Check for batt...

Page 74: ...ion Refer to Pages A 1 through A 3 as appropriate 1 Service the battery as necessary by cleaning and tightening connections recharging or replacing the battery or replacing damaged battery cables p 4...

Page 75: ...nt thermostat which might not be opening fully p 4 8 11 If loose tighten the ring terminal on coolant sender E2 p 9 6 12 Test coolant sender E2 and replace if necessary p 9 6 13 Disconnect connector P...

Page 76: ...el supply tank probably is such that the genset will run out of fuel before the propulsion engines 3 Remove combustion air or exhaust system blockages 4 Open any closed fuel supply and return valves 5...

Page 77: ...pump belt p 4 9 5 Check for a worn raw water impeller and replace as necessary p 4 10 6 Check the bottom of the hull for any blockage at the through hull fitting 7 Disconnect connector P1 black from t...

Page 78: ...is such that the genset will run out of fuel before the propulsion engines 3 Remove combustion air or exhaust system blockages 4 Prime the engine fuel system for at least 30 seconds p 3 3 5 Check all...

Page 79: ...was engaged Frequency jumped to more than 70 Hz for 40 milliseconds or to more than 2percent over nominal for 6 seconds Corrective Action 1 Check for a tripped genset circuit breaker reset it if nece...

Page 80: ...e 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 combustion air or exhaust system blockages 4 Prime th...

Page 81: ...r leaks tighten as necessary and reprime 6 Replace the fuel filters and reprime p 4 5 7 Conduct a fuel pump test and replace if necessary p 6 4 8 Check for proper operation of the governor actuator an...

Page 82: ...g and connectors as necessary 3 Test sender E2 and replace as necessary Page 9 6 4 Replace the genset controller p 9 1 LOSS OF AC VOLTAGE SENSE CODE NO 27 Control Logic The genset Controller lost VAC...

Page 83: ...stem for at least 30 seconds p 3 3 6 Check all fuel filters and fittings for fuel and air leaks tighten as necessary and reprime 7 Replace the fuel filters and reprime p 4 5 8 Conduct a fuel pump test...

Page 84: ...e brushes and slip rings as necessary p 8 4 and test the generator field stator and quadra ture windings for opens and shorts p 8 5 Replace a stator or rotor with faulty windings GENERATOR ROTOR FAULT...

Page 85: ...UST TEMPERATURE CODE NO 58 Control Logic Exhaust temperature exceeded design limits due to lack of water delivered to the exhaust water mixer Corrective Action Refer to Pages A 1 through A 3 as approp...

Page 86: ...n 3 8 NPT Coolant Capacity 2 2 quart 2 1 liter Coolant Flow 60 Hz 50 Hz 3 5 gpm 13 liter min 3 0 gpm 16 liter min Raw Water Flow 60 Hz 50 Hz 5 0 gpm 19 liter min 4 0 gpm 15 liter min Maximum Raw Water...

Page 87: ...Redistribution or publication of this document by any means is strictly prohibited...

Page 88: ...A 1 0098 8371 WIRING DIAGRAM Redistribution or publication of this document by any means is strictly prohibited...

Page 89: ...A 2 0098 8374 GENERATOR CONNECTION DIAGRAM Redistribution or publication of this document by any means is strictly prohibited...

Page 90: ...A 3 338 4625 CONTROL WIRING HARNESS Redistribution or publication of this document by any means is strictly prohibited...

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