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Onan MDKBL - Service Manual

Onan MDKBL
93 pages
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Table of Contents

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Onan MDKBL Specifications

General IconGeneral
BrandOnan
ModelMDKBL
CategoryPortable Generator
LanguageEnglish

Summary

Safety Precautions

Engine Exhaust Hazards

Details dangers of engine exhaust, including carbon monoxide poisoning symptoms.

Generator Voltage Hazards

Warns about the deadly nature of generator voltage and safe electrical practices.

Diesel Fuel Hazards

Highlights the combustibility of diesel fuel and ignition source warnings.

Moving Parts Hazards

Warns about severe personal injury or death from moving engine parts.

Battery Gas Hazards

Details the explosive nature of battery gas and safety precautions.

Flammable Vapor and Diesel Engines

Explains risks of flammable vapor causing engine overspeed and potential death.

2. Control Panel

Digital Display Functions

Details the functions of the e-Series Digital Display, including start, stop, and priming.

Genset Status Screens

Explains the three screen pages displaying genset status and parameters.

Fault Screen

Describes the fault screen display, fault number, and description after shutdown.

Fault History and Pre-Alarms

Covers displaying fault history and engine pre-alarm conditions.

Configuring Genset Controller

Explains how to configure a replacement controller and reset the hour meter.

3. Operation

Fuel Requirements

Specifies recommended diesel fuel types, cetane number, and lubricity.

Engine Oil Recommendations

Advises on API service category and SAE viscosity grade for engine oil.

Engine Coolant

Details recommended coolant mixture and toxicity disposal.

Pre-Start Checks

Lists critical checks before starting the genset, including exhaust gas safety.

Starting the Genset

Provides step-by-step instructions for starting the genset from control panels.

Stopping the Genset

Explains the procedure for stopping the genset, including cool-down.

Emergency Stop Procedure

Details how to use the emergency stop switch and reset it.

Loading the Genset

Explains how to determine and manage load based on genset rating and conditions.

4. Periodic Maintenance

General Inspection

Covers daily and pre-start inspections of various genset systems.

Maintaining Battery and Connections

Provides safety and procedural steps for battery maintenance.

Checking Engine Oil Level

Offers detailed steps and safety warnings for checking engine oil.

Changing Engine Oil and Filter

Provides a step-by-step guide for changing engine oil and filter.

Draining and Replacing Fuel Filters

Explains how to drain water/sediment and replace fuel filters.

Maintaining Engine Cooling System

Covers the overview, coolant mixture, and replenishing coolant.

Draining and Cleaning Cooling System

Provides steps for draining, cleaning, and flushing the cooling system.

Replacing Raw Water Pump Impeller

Provides detailed steps for replacing the raw water pump impeller.

Adjusting V-Belt Tension

Explains how to adjust the V-belt tension for the alternator and pump.

Replacing the Thermostat

Provides a step-by-step procedure for replacing the engine thermostat.

5. Genset Control

Configuring Replacement Controller

Explains controller configuration based on genset model and generator type.

Removing and Replacing Controller

Provides step-by-step instructions for controller removal and replacement.

Major Genset Controller Functions

Describes key functions like initialization, fuel prime, startup, stop, and voltage control.

Engine Oil Pressure Sender (E1)

Explains the function, installation, and testing of the oil pressure sender.

Engine Coolant Temperature Sender (E2)

Details the function, installation, and testing of the coolant temperature sender.

Raw Water Flow Switch (S6)

Describes the function, installation, and testing of the raw water flow switch.

High Exhaust Temperature Switch (S5)

Explains the function and mounting of the high exhaust temperature switch.

Low Coolant Level Switch (S3)

Describes the function and mounting of the low coolant level switch.

Governor Actuator (A12)

Details the function, installation, and testing of the governor actuator.

6. Engine and Accessories

Major Engine Service

Refers to the Engine Workshop Manual for major engine service procedures.

7. Generator

Testing Generator Performance

Covers winding insulation resistance and winding resistance tests.

Generator Disassembly

Provides step-by-step instructions for safely disassembling the generator.

Generator Reassembly

Details the reverse procedure for reassembling the generator components.

Changing Generator Frequency

Describes how to reconfigure the generator for different frequencies.

Adjusting Generator Voltage

Provides instructions for adjusting the generator's output voltage.

8. Reconfiguring Voltage and Frequency

Changing Genset Frequency

Explains how to change the genset output frequency using jumpers.

Reconnecting the Generator

Provides steps for reconnecting the generator for the application voltage.

Adjusting Voltage via Digital Display

Details how to adjust voltage using the optional e-Series Digital Display.

Adjusting Voltage via Control Switch

Explains how to adjust voltage using the control switch and status lamps.

9. Troubleshooting

Troubleshooting with Digital Display

Guides on interpreting fault codes and displays on the e-Series Digital Display.

Troubleshooting with Status Lamp

Explains fault codes indicated by blinking status lamps on the control switch.

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