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MDKAL, MDKAA, MDKABwPrinted in U.S.A.981 0103B

CaliforniaProposition 65 WarningDiesel engine exhaust and some of its constituents are knownto the State of California to cause cancer, birth defects, andother reproductive harm.Redistribution or publication of this document,by any means, is strictly prohibited.

Table of ContentsSAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Fuel Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Engine Oil Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Fire Extinguisher Port—Gensets with Sound Shields . . . . . . . . . . . . . . . . . . . . . . . 6Typical Genset Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Genset-Mounted Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Remote Control Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Powering Appliances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Connections to Shore Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Resetting Line Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Genset Exercise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Genset Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Returning the Genset to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Changing Oil and Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Generator Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Engine Does Not Stop Running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Engine Does Not Crank from Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Engine Does Not Crank from Genset Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Engine Cranks but Does Not Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28“Check Engine” Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29“Check Generator” Fault Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Engine Lacks Power or Is Unstable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30No Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30HOW TO OBTAIN SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32INFORMATION FOR CALIFORNIA GENSET USERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 33MAINTENANCE RECORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341Redistribution or publication of this document,by any means, is strictly prohibited.

Safety PrecautionsThoroughly read the OPERATOR’S MANUALbefore operating the genset. Safe operationand top performance can be obtained only byproper operation and maintenance. Used engine oil has been identified by somestate and federal agencies as causing canceror reproductive toxicity. Do not ingest, inhale,or contact used oil or its vapors.The following symbols in this Manual alert you topotential hazards to the operator, service personnel and equipment. Do not work on the genset when mentally orphysically fatigued or after consuming alcoholor drugs.alerts you to an immediate hazardwhich will result in severe personal injury ordeath. Carefully follow all applicable local, state andfederal codes.alerts you to a hazard or unsafepractice which can result in severe personal injury or death. Do not step on the genset, as when enteringor leaving the engine room. The stress canbreak genset parts leading to possible fuel orexhaust leaks or electricution.WARNINGCAUTION alerts you to a hazard or unsafepractice which can result in personal injury orequipment damage.GENERATOR VOLTAGE IS DEADLY! Generator output connections must be madeby a qualified electrician in accordance withapplicable codes.Electricity, fuel, exhaust, moving parts and batteries present hazards which can result in severe personal injury or death. The genset must not be connected to the public utility or any other source of electrical power.Connection could lead to electrocution of utilityworkers, damage to equipment and fire. Anapproved switching device must be used toprevent interconnections.GENERAL PRECAUTIONS Keep ABC fire extinguishers handy. Make sure all fasteners are secure andtorqued properly. Use caution when working on live electricalequipment. Remove jewelry, make sure clothing and shoes are dry and stand on a drywooden platform on the ground or floor. Keep the genset and its compartment clean.Excess oil and oily rags can catch fire. Dirt andgear stowed in the compartment can restrictcooling air.FUEL IS FLAMMABLE AND EXPLOSIVE Let the engine cool down before removing thecoolant pressure cap or opening the coolantdrain. Hot coolant under pressure can sprayout and cause severe burns. Keep flames, cigarettes, sparks, pilot lights,electrical arc-producing equipment andswitches and all other sources of ignition wellaway from areas where fuel fumes are presentand areas sharing ventilation. Before working on the genset, disconnect thenegative (- ) battery cable at the battery to prevent starting. Fuel lines must be secured, free of leaks andseparated or shielded from electrical wiring. Use caution when making adjustments whilethe genset is running—hot, moving or electrically live parts can cause severe personal injury or death. Use approved non-conductive flexible fuelhose for fuel connections at the genset.2Redistribution or publication of this document,by any means, is strictly prohibited.

ENGINE EXHAUST IS DEADLY!BATTERY GAS IS EXPLOSIVE Learn the symptoms of carbon monoxide poisoning in this manual. Wear safety glasses and do not smoke whileservicing batteries. Never sleep in the vessel with the genset running unless the vessel is equipped with a working carbon monoxide detector. When disconnecting or reconnecting batterycables, always disconnect the negative (- )battery cable first and reconnect it last to reduce arcing. The exhaust system must be installed in accordance with the genset Installation Manualand be free of leaks.DO NOT OPERATE IN FLAMMABLE ANDEXPLOSIVE ENVIRONMENTS Make sure the bilge is adequately ventilatedwith a power exhauster.Flammable vapor can cause a diesel engine tooverspeed and become difficult to stop, resulting inpossible fire, explosion, severe personal injury anddeath. Do not operate a diesel-powered gensetwhere a flammable vapor environment can becreated by fuel spill, leak, etc., unless the genset is equipped with an automatic safety deviceto block the air intake and stop the engine. Theowners and operators of the genset are solely responsible for operating the genset safely. Contactyour authorized Onan/Cummins dealer or distributor for more information.MOVING PARTS CAN CAUSE SEVEREPERSONAL INJURY OR DEATH Do not wear loose clothing or jewelry nearmoving parts such as PTO shafts, fans, beltsand pulleys. Keep hands away from moving parts. Keep guards in place over fans, belts, pulleys,etc.POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE VESSELm-93Redistribution or publication of this document,by any means, is strictly prohibited.

SpecificationsMDKALMDKAAMDKABGENERATOR: Single-Bearing, 4-Pole Rotating Field, Brushless, Electronically Regulated ( 1%)60 Hz, 1-Ph Output @ 1.0 PF8.0 kW, 8.0 kVA10.5 kW, 10.5 kVA50 Hz, 1-Ph Output @ 1.0 PF6.5 kW, 6.5 kVA8.5 kW, 8.5 kVA60 Hz, 3-Ph Output @ 0.8 PF50 Hz, 3-Ph Output @ 0.8 PF12.5 kW, 12.5 kVA10.0 kW, 10.0 kVA8.0 kW, 10.0 kVA6.5 kW, 8.13 kVA10.5 kW, 13.1 kVA8.5 kW, 10.6 kVA12.5 kW, 15.6 kVA10.0 kW, 12.5 kVAFUEL CONSUMPTION:60 Hz: Full LoadHalf Load0.8 gph (3.0 liter/hr)0.5 gph (1.9 liter/hr)1.0 gph (3.8 liter/hr)0.6 gph (2.3 liter/hr)1.2 gph (4.5 liter/hr)0.7 gph (2.6 liter/hr)50 Hz: Full LoadHalf Load0.7 gph (2.6 liter/hr)0.4 gph (1.5 liter/hr)0.8 gph (3.0 liter/hr)0.5 gph (1.9 liter/hr)0.9 gph (3.4 liter/hr)0.5 gph (1.9 liter/hr)ENGINE: 4-Stroke Cycle, Indirect Injection Diesel, Water Cooled, Mechanically Governed (5% droop)Number of Cylinders344Bore2.99 inch (76 mm)2.99 inch (76 mm)3.07 inch (78 mm)Stroke3.09 inch (78.4 mm)2.90 inch (73.6 mm)3.09 inch (78.4 mm)Displacement68 inch3 (1124 cm3)81.5 inch3 (1335 cm3)91.4 inch3 (1498 cm3)Compression Ratio22:122:122:1Firing Order (Clockwise Rotation)1-2-31-2-4-31-2-4-3Fuel Injection Timing15.5 - 17.5 BTDC15.5 - 17.5 BTDC15.5 - 17.5 BTDC0.0071 - 0.0087 inch0.0071 - 0.0087 inch0.0071 - 0.0087 inchValve Lash (cold)(0.18 - 0.22 mm)(0.18 - 0.22 mm)(0.18 - 0.22 mm)Engine Oil CapacityEngine Oil Drain ConnectionCoolant CapacityCoolant Flow Rate:60 Hz50 Hz4.2 quart (4.0 liter)3/8 NPT4.2 quart (4.0 liter)5.0 gpm (19 liter/min)4.2 gpm (16 liter/min)4.5 quart (4.3 liter)3/8 NPT5.3 quart (5.0 liter)5.0 gpm (19 liter/min)4.2 gpm (16 liter/min)4.5 quart (4.3 liter)3/8 NPT5.3 quart (5.0 liter)5.0 gpm (19 liter/min)4.2 gpm (16 liter/min)Sea Water Flow Rate: 60 Hz50 Hz6.0 gpm (23 liter/min)5.0 gpm (19 liter/min)6.0 gpm (23 liter/min)5.0 gpm (19 liter/min)6.0 gpm (23 liter/min)5.0 gpm (19 liter/min)4 feet (1.2 m)1.0 inch (25.4 mm) ID Hose4 feet (1.2 m)1/4 NPT female1/4 NPT female3 inch (76 mm) Hg2.0 inch (50.8 mm) ID Hose1-1/4 NPT4 feet (1.2 m)1.0 inch (25.4 mm) ID Hose4 feet (1.2 m)1/4 NPT female1/4 NPT female3 inch (76 mm) Hg2.0 inch (50.8 mm) ID Hose1-1/4 NPT4 feet (1.2 m)1.0 inch (25.4 mm) ID Hose4 feet (1.2 m)1/4 NPT female1/4 NPT female3 inch (76 mm) Hg2.0 inch (50.8 mm) ID Hose1-1/4 NPT12 volts360 amps10 amps12 volts500 amps10 amps12 volts500 amps10 amps625 lbs (284 kg)37.3 x 18.9 x 22.1 inch(946 x 479 x 562 mm)625 lbs (284 kg)37.3 x 18.9 x 22.1 inch(946 x 479 x 562 mm)625 lbs (284 kg)710 lbs (322 kg)36.0 x 22.4 x 23.5 inch40.8 x 22.4 x 23.5 inch(915 x 568 x 596 mm)(1037 x 568 x 596 mm)* - Isolated ground and 24 volt battery systems are available as options.710 lbs (322 kg)40.8 x 22.4 x 23.5 inch(1037 x 568 x 596 mm)Maximum Sea Water Pump LiftSea Water Inlet ConnectionMaximum Fuel Pump LiftFuel Supply ConnectionFuel Return ConnectionMaximum Exhaust Back PressureWet Exhaust Outlet ConnectionDry Exhaust Outlet ConnectionBATTERIES:Nominal Battery Voltage*Minimum CCA RatingCharging Alternator OutputAPPROXIMATE WEIGHTS AND DIMENSIONS:Without Sound ShieldWet WeightDimensions: L x W x H540 lbs (245 kg)32.5 x 18.9 x 22.1 inch(826 x 479 x 562 mm)With Sound ShieldWet WeightDimensions: L x W x H4Redistribution or publication of this document,by any means, is strictly prohibited.

IntroductionABOUT THIS MANUALThis manual covers operation and maintenance ofthe model MDKAL, MDKAA and MDKAB generatorsets (gensets). Study this manual carefully and observe all of its instructions and precautions. Usingthe genset properly and maintaining it regularly willpromote longer genset life, better performance, andsafer operation. Each operator should becomethoroughly familiar with this manual. Keep thismanual in a convenient location for quick reference.10.5MDKAA/92989AA980123456MODEL IDENTIFICATIONSKB1.3U6D2RAWhen you call for service or parts have the gensetmodel number and serial number ready (Figure 1).For ready reference, record these numbers in theboxes shown.FUEL RECOMMENDATIONSHigh quality fuel is necessary for good performanceand long engine life. Use No. 2 diesel fuel(ASTM 2-D) with a Cetane number of not less than45 and sulfur content of not more than 0.5 percent(by weight). Where fuel is exposed to cold ambienttemperatures, use fuel that has a cloud point (temperature at which wax crystals begin to form) atleast 10 degrees below the lowest expected fueltemperature.RECORD MODEL AND SERIAL NUMBERS HEREWARNING Diesel fuel is combustible and cancause severe personal injury or death. Do notsmoke near fuel tanks or fuel-burning equipment or in areas sharing ventilation with suchequipment. Keep flames, sparks, pilot flames,electrical arcs and switches and all othersources of ignition well away. Keep a type ABCfire extinguisher handy.MODEL NUMBERSERIAL NUMBERFIGURE 1. TYPICAL NAMEPLATE5Redistribution or publication of this document,by any means, is strictly prohibited.

ENGINE OIL RECOMMENDATIONSUse premium quality motor oil. Look for the API(American Petroleum Institute) classification anduse Class CG-4, CF-4, CF or better oil. Also look forthe SAE (Society of Automotive Engineers) viscosity grade. Referring to Figure 2, choose the viscosity grade appropriate for the range of ambient temperatures expected before the next scheduled oilchange. Multi-grade oils such as SAE 15W-40 arerecommended for year-round use.FIGURE 2. SAE VISCOSITY GRADE vs. AMBIENTTEMPERATUREBATTERIESThe genset requires either a 12 volt or 24 volt battery to power its control and starting circuits. Reliable genset starting and starter service life dependupon adequate battery system capacity and maintenance. See Specifications for battery requirements and Periodic Maintenance for battery care.FIRE EXTINGUISHER PORT—GENSETSWITH SOUND SHIELDSGensets with sound shields have a fire extinguisherport accessible by breaking through the circle onthe 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 smallerthan 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 sound shield.2. Shut down engines, generators and blowers.3. Break through the circle on the label with thenozzle and discharge the full contents of thefire extinguisher.TYPICAL GENSET CONFIGURATIONFigures 4 and 5 illustrate the typical configuration ofa genset, showing the components on the serviceand non-service sides.FIGURE 3. FIRE EXTINGUISHER PORT6Redistribution or publication of this document,by any means, is strictly prohibited.

COMBUSTIONAIR STICKAIR INTAKERESONATORFUELPUMPFUELFILTERSEA WATERINLETFUELSOLENOIDOIL FILLSEA WATERHOSEOILFILTERFIGURE 4. TYPICAL GENSET CONFIGURATION—COMPONENTS ON SERVICE SIDE7Redistribution or publication of this document,by any means, is strictly prohibited.

BATTERYCHARGINGALTERNATORHIGH ENGINETEMPERATURESWITCHBATTERYPOS ( ) M8COOLANTPRESSURECAPLOW COOLANTLEVEL SWITCH(OPTIONAL)HIGH EXHAUSTTEMPERATURESWITCH RS(OPTIONAL)ZINCANODEHEAT EX CHANGERBLOCK DRAINCOCKBATTERYNEG ( ) M10STARTERMOTORSEAWATERHOSEWET EX HAUSTOUTLETFIGURE 5. TYPICAL GENSET CONFIGURATION—COMPONENTS ON NON-SERVICE SIDE8Redistribution or publication of this document,by any means, is strictly prohibited.

installed. Push the button to read M2 and M3 at thegenset.“Check Engine” Fault Breaker (CB2): Shutsdown the genset when one of the following faultconditions causes it to trip: overvoltage, overspeed,low oil pressure, high exhaust temperature, highcoolant temperature and low coolant level (optional). Push the reset button to reset.“Check Generator” Fault Breaker (CB5): Shutsdown the genset when high generator quadraturewinding current causes it to trip. Push the reset button to reset.DC Circuit Breaker (CB1): Protects the high-current (DC) glow plug circuits from shorts to ground.The genset will stop if tripped. Reset with handle.Emergency Stop Breaker (CB4): A rocker-switchtype of circuit breaker that protects the genset control circuits (DC) from shorts to ground. The gensetwill stop if the circuit breaker trips or the rocker ispushed to Stop. Push the rocker On to reset.GENSET-MOUNTED CONTROL PANELFigure 6 illustrates a typical control panel with optional engine gauges.Start-Stop-Prime/Preheat Switch (S1): Starts thegenset when held at Start and stops the gensetwhen momentarily touched to Stop. Holding theswitch at Stop causes the glow plugs to preheat thecombustions chambers and the fuel lift pump toprime the fuel system.Hour Meter (M1): Indicates the number of hoursthe genset has run. It cannot be reset.Engine Gauges (M2, M3, M4): Optional—indicateengine oil pressure, coolant temperature and control system DC voltage. If remote gauges have beeninstalled, push gauge switch (S6) in to read M2 andM3 at the genset.Gauge Switch (S6): Momentary contact switchused only when remote gauges have )(CB1)(CB5)(M1)(S1)(CB2)(CB4)FIGURE 6. GENSET-MOUNTED CONTROL PANEL9Redistribution or publication of this document,by any means, is strictly prohibited.

installed, oil pressure and coolant temperature normally display at the remote panel rather than at thegenset. A momentary gauge switch on the gensetpanel (Figure 6) can be provided to read the gaugeson the genset panel.REMOTE CONTROL PANELSAvailable remote control panels are shown in Figure 7. The switch and gauges function the sameway as the ones on the genset-mounted controlpanel. When a remote panel with gauges isFIGURE 7. AV

ABOUT THIS MANUAL This manual covers operation and maintenance of the model MDKAL, MDKAA and MDKAB generator sets (gensets). Study this manual carefully and ob-serve all of its instructions and precautions. Using the genset properly and maintaining it regularly will promote longer genset life, better performance, and safer operation.

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