CUMMINS MDKBK, MDKBM, MDKBN, MDKBP, MDKBR Installation Manual

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Installation Manual
MDKBK MDKBL MDKBM MDKBN MDKBP MDKBR MDKBS
981-0642B 11-05
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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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Table of Contents
SECTION PAGE
SAFETY PRECAUTIONS iii. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1. INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About this Manual 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards for Safety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Outline Drawings 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2. LOCATION AND MOUNTING 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. VENTILATION 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Carbon Monoxide 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4. FUEL CONNECTIONS 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. ENGINE COOLING 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Raw Water Pickup Test 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Keel Cooling 5-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6. ENGINE EXHAUST 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wet Exhaust Systems 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust Water Separator Backflow Test 6-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dry Exhaust Systems 6-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7. ELECTRICAL CONNECTIONS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Connections 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Connections 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Genset Ground (Vessel Bond) 7-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Connector 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
External Customer Connections 7-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional Network Interface Module (NIM) 7-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION PAGE
8. RECONFIGURING VOLTAGE AND FREQUENCY 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9. INSTALLATION REVIEW AND STARTUP 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10. SPECIFICATIONS 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (SHEET 1) A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (SHEET 2) A-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRING DIAGRAM (SHEET 3) A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBL (SHEET 1) A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBL (SHEET 2) A-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBM, MDKBN (SHEET 1) A-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBM, MDKBN (SHEET 2) A-7. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBP, MDKBR (SHEET 1) A-8. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBP, MDKBR (SHEET 2) A-9. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBP, MDKBR (SHEET 3) A-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBS (SHEET 1) A-11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBS (SHEET 2) A-12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBS (SHEET 3) A-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OUTLINE DRAWING—MDKBK (SHEET 1) A-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 proper­ly.
The following symbols in this manual alert you to potential hazards to the operator, service person and equipment.
DANGER
that will result in severe personal injury or death.
WARNING
practice that can result in severe personal inju­ry or death.
CAUTION
practice that can result in personal injury or equipment damage.
Electricity, fuel, exhaust, moving parts and batter­ies present hazards which can result in severe per­sonal injury or death.
alerts you to an immediate hazard
alerts you to a hazard or unsafe
alerts you to a hazard or unsafe
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 se­vere 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 accor­dance with local environmental regulations.
Keep multi-class ABC fire extinguishers
handy. Class A fires involve ordinary combus­tible 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)
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 nega­tive (–) 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.
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 electri­cian in accordance with applicable codes.
The genset must not be connected to shore
power or to any other source of electrical pow­er. Back-feed to shore power can cause elec­tric shock resulting in severe personal injury or death and damage to equipment. An approved switching device must be used to prevent inter­connections.
Use caution when working on live electrical
equipment. Remove jewelry, make sure cloth­ing and shoes are dry, stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles.
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ENGINE EXHAUST IS DEADLY
BATTERY GAS IS EXPLOSIVE
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.
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 equip­ment. Keep flames, sparks, pilot lights, arc­producing equipment and all other sources of ignition well away.
Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring.
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-10
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1. Introduction
ABOUT THIS MANUAL
This manual is a guide for the installation of the gen­erator sets (gensets) listed on the front cover. Prop­er installation is essential for top performance. Read through this manual before starting the installation.
This manual addresses the following aspects of the installation:
Location and mounting
Engine exhaust discharge and silencing
Engine cooling
Genset room ventilation
Fuel connections
Electrical connections
Batteries
Bonding for grounding
Accessibility for operation and maintenance
Noise and vibration.
Guard (USCG) regulations is mandatory for boats in U. S. waters. The American Boat and Yacht Council (ABYC) and the National Fire Protection Associa­tion (NFPA) are typical of agencies that publish safety standards for the construction and installa­tion of marine equipment. It is suggested that you obtain the following standards:
USCG regulations are under Titles 33 and 46 of
the Code of Federal Regulations (CFR),
U.S. Government Printing Office Washington, D.C. 20404.
NFPA No. 302, Pleasure and Commercial Mo-
tor Craft,
National Fire Protection Association Batterymarch Park Quincy, MA 02269
Standards and Recommended Practices For
Small Craft,
American Boat and Yacht Council, Inc.
3069 Solomons Island Road Edgewater, MD 21037
WARNING
tem. It can stop without warning. Children, per­sons with physical or mental limitations, and pets could suffer personal injury or death. A per­sonal attendant, redundant power or an alarm system must be used if genset operation is criti­cal.
See the genset Operator’s Manual for operation and maintenance and the Service Manual for ser­vice.
Note: Manuals are updated from time to time to re­flect changes in the equipment and its specifica­tions. For this reason, only the copy of the installa­tion manual supplied with the genset should be used as a guide for the installation.
This genset is not a life support sys-
STANDARDS FOR SAFETY
You must find out which standards for safety are ap­plicable. Compliance with United States Coast
Particular attention should be paid to ABYC P-1,
Installation of Exhaust Systems for Propulsion and Auxiliary Machinery, ABYC E-11, AC and DC Elec- trical Systems on Boats and ABYC A-27, Alternat­ing Current (AC) Generator Sets.
OUTLINE DRAWINGS
See the applicable OUTLINE DRAWING (p. A-4 and following) for installation details: mounting bolt hole locations, connection points (fuel, battery, raw water, exhaust, remote control and AC output), sizes and types of fittings, overall dimensions, etc. See your Onan dealer for large-scale copies of the applicable drawings.
WARNING
severe personal injury, death and equipment damage. The installer must be qualified to per­form installation of electrical and mechanical equipment.
Improper installation can result in
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2. Location and Mounting
The genset has a single lifting eye, which is accessi­ble through an access cover if the genset has an en­closure. Refer to the applicable OUTLINE DRAW­ING (p. A-4 and following) for the weight of the gen­set and make provisions accordingly for safe han­dling.
LOCATION
See the other sections titled Ventilation, Fuel Sup­ply, Engine Cooling and Engine Exhaust for addi-
tional considerations that bear on location.
The genset is not “ignition protected” and therefore not permitted under USCG regulation 33CFR183 to be located in a gasoline fuel environment. If the boat has gasoline-fueled propulsion engines, the genset will have to be located where it can be isolated from the gasoline fuel system by approved methods.
WARNING
fumes causing severe personal injury or death. Approved methods must be used to isolate the genset from a gasoline fuel environment.
The genset can ignite gasoline
side at least 2 inches (50 mm) for air flow out. See the applicable OUTLINE DRAWING (p. A-4 and fol­lowing).
Make sure there is access for:
Starting and stopping the genset
Resetting the line circuit breakers (when pro-
vided)
Checking, filling and draining engine oil
Changing the engine oil filter
Changing the fuel filter
Checking, filling and draining engine coolant
Making fuel connections
Making battery and ground connections
Replacing coolant and exhaust hoses
Replacing the raw water pump impeller (when
provided)
Replacing the V-belt
Because of noise, vibration and fumes, the genera­tor compartment should be located as far from living quarters as practical.
Locate the genset where there will be enough room to perform periodic maintenance and service. Non­service sides should have at least 2 inches (50 mm) of clearance. The front should have at least 4 inches (100 mm) of clearance for air flow in and the right
MOUNTING
The genset has integral vibration isolators. The sup­porting structure underneath should be level and able to support the weight of the genset. Floor or frame stiffness should be greatest under the vibra­tion isolators. Secure the genset with four bolts. See the applicable OUTLINE DRAWING (p. A-4 and fol­lowing) for the locations of the mounting bolt holes.
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3. Ventilation
WARNING
VAPORS ARE EXPLOSIVE! Failure to provide proper ventilation can result in asphyxiation, fire and explosion. The ventilation system must meet applicable standards and regulations, in­cluding USCG, NFPA and ABYC (p. 1-1).
EXHAUST GAS IS DEADLY—FUEL
VENTILATION
Ventilation is required to prevent dangerous con­centrations of fuel vapors and exhaust fumes, hold down compartment temperatures and provide com­bustion air. The highest compartment temperatures can occur just after the boat has been docked and the engines have been shut down.
To promote natural convective flow, good air ex­change and fresh air for combustion and generator cooling, ventilating air should enter near the bottom of the compartment at the front near the air inlet and exit near the top at the right side. The free-air area of the inlet air cowl should be at least twice that of the duct. Use 40 in tions for inlet and outlet air duct sizes and free-air areas of screens and louvers. Do not use flush air inlets or louvered transom outlets, which are easily blocked.
2
(258 cm2) as the basis for calcula-
Operating a genset in ambient temperatures above 104° F (40° C) will result in noticeable loss of power. Operating a genset in ambient temperatures higher than 122° F (50° C) will reduce the life of electrical components, generator windings, rubber and other construction materials.
When calculating air flow required for combustion and ventilation, refer to Section 10. Specifications for data regarding air flow and heat radiated to the room.
CARBON MONOXIDE
All openings and feed-through holes for wiring, con­duit, pipe and hose must be sealed to prevent ex­haust gases from entering the rest of the boat. Wir­ing conduit must be sealed inside as well as outside.
Cabin plumbing drains must have approved traps to prevent the entrance of exhaust gases from outside.
Carbon monoxide (CO) detectors, listed for marine applications, should be installed in the living quar­ters of the boat. Wind shifts, boat motion, exhaust from other boats at dockside and other conditions can cause exposure to harmful concentrations of carbon monoxide even when proper ventilation is provided and living quarters are sealed off from en­gine rooms.
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4. Fuel Connections
WARNING
Diesel Fuel can lead to fire. Fuel tank construc­tion, location, installation, bonding for ground­ing, ventilation, piping, inspection and leak test­ing must be in accordance with applicable stan­dards and regulations, including USCG, NFPA and ABYC (p. 1-1).
CAUTION
piping. The trace of sulfur in diesel fuel attacks galvanized (zinc) coatings causing debris that can clog fuel filters, pumps and injectors.
Improper storage and handling of
Do not use galvanized fuel tanks or
Fuel
See the Operator’s Manual for recommended fuel.
Fuel Filters
The genset is equipped with a water-separator fuel filter. It is recommended that a 10 to 30 micron water-separator fuel filter be installed in the fuel supply system to protect the fuel lift pump.
Fuel Line Sizing
An inside diameter of 5/16 inch (8 mm) is recom­mended for fuel lines and hoses. An inside diameter of 1/4 inch (7 mm) should be considered in applica­tions where fuel lines are short and lift minimal. See Fuel Lift in this section. Larger diameter fuel lines
are harder to prime and keep primed and are thus more likely to cause disruption of genset service.
Run fuel lines as directly as possible avoiding dips and crests that trap air and cause hard priming.
Fuel Pickup Tube
A separate fuel pickup tube and supply line is rec­ommended for each genset. Shared pickup tubes and distribution manifolds can lead to fuel starvation and difficult priming.
See Fuel Line Sizing in this section for recom­mended sizing.
Fuel Fittings
Two 1/4-18 NPTF fittings are provided for fuel sup­ply and return connections. See the appropriate OUTLINE DRAWING (p. A-4 and following). Fuel hose adapter fittings are available from Onan.
Fuel Hoses
Use USCG TYPE A1 or ISO 7840-A1 fuel hoses. See Fuel Line Sizing in this section for recom­mended sizing.
The fuel hoses connected at the genset must be non-conductive so that the fuel lines do not become paths for cranking current. (Because the fuel tanks are required to be bonded to the common negative [–] grounding system of the boat, conductive fuel lines connected directly to the genset will carry cranking currents.)
WARNING
cranking current. Use non-conductive fuel hoses for connections at the genset to prevent the fuel lines from becoming paths for cranking current.
Fire can result when fuel lines carry
In a common fuel supply tank the genset pickup tubes should be shorter than the propulsion engine pickup tubes to prevent the gensets from being able to empty the fuel tanks.
Make sure the fuel tanks are large enough to cool the returning fuel.
Fuel Shutoff Valves
A fuel shutoff valve is required at the fuel tank if the end of the fuel line is located below the highest level of fuel in the tank.
An approved method is required to prevent flow when the engine is not running if the highest level of fuel in the supply tank is above the fuel injectors.
Fuel Lift
The fuel lift pump on the genset has a fuel lift capa­bility (suction) of 4 feet (1.2 meters). Note that the pump must overcome the resistance to fuel flow in hoses, tubing, fittings, valves and filters as well as the actual lift in elevation.
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5. Engine Cooling
The engine is cooled by a pressurized, closed-loop liquid cooling system in which coolant is pumped through passages in the engine block, head and ex­haust manifold (Figure 5-1 or 5-2). Heat is carried away from the coolant by a keel cooler or raw water (sea water) heat exchanger. A gear-driven raw wa­ter pump is provided if the genset has a heat ex­changer or wet exhaust. See the appropriate OUT­LINE DRAWING (p. A-4 and following) for connec­tion points and fitting sizes.
SYSTEM COMPONENTS
Raw Water Pump
The raw water pump can deliver the required flow of cooling water against a maximum lift (suction) of 4 feet (1.22 meters). Lift is a combination of the ac­tual vertical lift and the resistance to flow caused by the hoses, strainer, sea cock and through-hull fit­ting.
Raw Water Hose
Use SAE 20R4 or equivalent hose that is able to re­sist a slight vacuum without collapsing. The fitting on the raw water pump inlet is sized for 1 inch (25.4 mm) internal diameter hose. This size should be used for all hoses and pipes in the raw water pick­up line.
Raw Water Strainer
The raw water strainer should be located below and as close to the raw water pump as practical. The basket must be removeable for cleaning. Fill the sea
water strainer for faster priming at startup if it is above the water line.
Sea Cock
Install a bronze, full-flow sea cock on the through­hull fitting.
Through-Hull Fitting and Strainer
The through-hull fitting should be as close to the genset as possible. If the strainer has slotted open­ings, the slots must be parallel to the keel for best flow when the boat is under way. Through-hull fit­tings should be staggered along the keel so that downstream fittings are not starved.
CAUTION
hull fitting. A forward-facing scoop can develop enough ram pressure to flood the engine. A rear-facing scoop can develop enough suction to impede flow.
Do not use a scoop-type through-
Siphon Break
CAUTION
result of failing to install a required siphon break is not covered by Warranty.
Conduct the RAW WATER PICKUP TEST to deter­mine whether a siphon break is required to prevent the muffler and engine from being flooded with floatation water (Figure 6-2). The top panel of an en­closed genset has knockouts for the hoses to pass through. A siphon break kit is available from Onan. The kit has hole grommets.
To keep leaks from spilling on the genset, do not mount the siphon break directly above the genset.
Engine damage due to flooding as a
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Coolant Recovery Tank
The coolant recovery tank kit shipped with the gen­set must be installed for proper operation of the cooling system. Follow the instructions in the kit.
The tank must be accessible for daily inspection and refilling. The genset enclosure (if provided) has
holes for mounting the tank on the engine end. For gensets not provided with an enclosure, mount the tank on a bulkhead within reach of the hoses and slightly above or at the same height as the pressure cap. Fill the tank in accordance with the Operator’s Manual.
Initial Coolant Fill
1. Close the sea cock and disconnect the raw wa­ter pickup hose from the genset. Alternatively, connect a clear plastic hose to the strainer or sea cock.
2. Raise the end of the hose above expected wa­ter level and open the sea cock. The water line
is at the level visible in a clear plastic hose or where water just begins to spill as the end of the hose is lowered. While the boat is still docked,
mark the level on the genset enclosure.
3. Operate the boat through its speed range, for­ward and reverse. While the boat is operating, have someone monitor the water level in the hose and mark the highest level on the genset.
CAUTION
Running the engine without coolant
can cause damage not covered by Warranty.
The genset is normally shipped from the factory with coolant, unless prohibited by shipping regulations. Fill the system, if necessary, in accordance with the Operator’s Manual.
Note: Keel-cooled gensets are only partially filled with coolant. Coolant must be added to fill the keel cooler and expansion tank.
RAW WATER PICKUP TEST
Objective
The objective is to determine the elevation of the water line relative to the genset under all anticipated uses and speeds of the boat.
Method
When the boat is ready for its sea trials and loaded to its maximum rated capacity:
Requirement
A siphon break must be installed if the engine ex­haust-water mixer (Figure 6-2) is not at least 6 inch­es (152 mm) above both water lines (docked and moving).
Note: If the water line when the boat is moving is much higher than when the boat is docked, the differ­ence could be due to the through-hull fitting or its location. If the through-hull fitting is of the forward­facing scoop-type designed to create ram pressure, replace it with a flush-type fitting. Another possibility might be to move the fitting to a location where the dynamic hull pressure is less.
KEEL COOLING
When sizing the keel cooler, refer to Section 10. Specifications for data regarding fitting sizes, en-
gine coolant capacity, thermostat opening tempera­ture, coolant flow rate, heat rejection to coolant and maximum coolant friction head.
5-2
Page 18
OPTIONAL LOW COOLANT
LEVEL SENSOR LOCATION
COOLANT PUMP
RAW WATER PUMP
RAW WATER FLOW SENSOR
COOLANT
THERMOSTAT
BULKHEAD FITTING ON
RAW WATER IN FROM
RIGHT OR LEFT SIDE
EXHAUST MANIFOLD & COOLANT RESERVOIR
WITH PRESSURE CAP AND COOLANT FILL
NECK. FILL NECK HAS HOSE BARB FOR
CONNECTING COOLANT RECOVERY TANK
COOLANT
DRAIN VALVE
ZINC
ANODE
BLOCK DRAIN VALVE
(COOLANT)
RAW WATER CLEANOUT
COVER (BOTH ENDS)
RAW WATER DRAIN PLUG
(BOTH ENDS)
EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH
EXHAUST & RAW WATER OUT
TO BULKHEAD FITTING ON RIGHT OR
LEFT SIDE
RAW WATER HOSE TO
EXHAUST-WATER
MIXER—WHEN REQUIRED,
REPLACE WITH SIPHON
BREAK AND CONNECTING
HOSES
COOLANT
COOLANT
RAW WATER
RAW WATER
FIGURE 5-1. ENGINE COOLING SYSTEM—MDKBK, MDKBL, MDKBM, MDKBN
5-3
Page 19
RAW WATER TO PUMP FROM
BULKHEAD FITTING ON
RIGHT OR LEFT SIDE
RAW
WATER
PUMP
RAW WATER HOSE TO
EXHAUST-WATER
MIXER—WHEN REQUIRED,
REPLACE WITH SIPHON
BREAK AND CONNECTING
HOSES
COOLANT RESERVOIR WITH PRESSURE CAP AND COOLANT FILL NECK. FILL NECK HAS HOSE BARB
FOR CONNECTING COOLANT RECOVERY TANK
RAW WATER FLOW SWITCH
(IN PUMP-TO-HEAT EXCHANGER HOSE)
LOCATION, OPTIONAL LOW
COOLANT LEVEL SENSOR
COOLANT
THERMOSTAT
HOUSING
COOLANT
TEMPERATURE
SENSOR
COOLANT
PUMP PULLEY
LOCATION, BLOCK
DRAIN VALVE
(COOLANT)
ZINC ANODE
COOLANT DRAIN VALVE
RAW WATER PLUGS
(UNDERNEATH)
FIGURE 5-2. ENGINE COOLING SYSTEM—MDKBP, MDKBR, MDKBS
EXHAUST & RAW WATER OUT
TO BULKHEAD FITTING ON RIGHT
OR LEFT SIDE
RAW WATER CLEANOUT COVER
(BOTH ENDS—MAKE SURE TO
RECONNECT GROUND STRAP ON
THIS END WITH COVER SCREW)
EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH
COOLANT
RAW WATER
5-4
Page 20
6. Engine Exhaust
WET EXHAUST SYSTEMS
WARNING
haust system must be leak-free and convey all exhaust outside, away from windows, doors and vents.
Figure 6-1 illustrates a typical exhaust system where the siphon point is above the load water line and Figure 6-2 where it is below. See Engine Cool- ing (Page 5-1) regarding raw water connections. The installation must comply with applicable stan­dards and regulations, including those of the USCG and ABYC (p. 1-1)
A separate engine exhaust system must be installed for each genset. It must be isolated from all other engine exhaust systems.
Mufflers, water separators and siphon breaks are available as kits from Onan.
EXHAUST GAS IS DEADLY! The ex-
Hose and Hose Fitting Diameters
are no sags. The entire run of hose must be accessible for regular, visual inspections and replacement.
Hose Clamps
Use two stainless steel hose clamps at least 1/2 inch (12.7 mm) wide to clamp each end of each hose.
Muffler
Install an approved muffler as close a practical to the engine. For optimum silencing, the length of hose between the engine and muffler should not ex­ceed 6 feet (2 meter). The muffler inlet should be a minimum of 1 foot (305 mm) below the exhaust-wa­ter mixer and the outlet should be vertical.
The base of the muffler should not be more than 54 inches (1.4 meter) below the water separator (Figure 6-1) or 48 inches (1.2 meter) below the crest in the piping (Figure 6-2).
No hose or hose fitting in the exhaust system may have a smaller inside diameter than the engine out­let. If the total run of exhaust hose is more than
20 feet (6 meters), measure exhaust back pressure and use larger diameter hose if back pressure ex­ceeds specifications. See Section 10. Specifica- tions.
Exhaust Hose
Use hose that has been approved for wet exhaust systems. Approved hose and stainless steel elbows are available from Onan. Horizontal runs of hose must slope down at least 1/2 inch per foot (42 mm/meter) and be supported such that there
Mount the muffler such that air can circulate under­neath to prevent condensation and mold.
Exhaust Water Separator
When an exhaust water separator is used (Fig- ure 6-1), the muffler outlet and water separator inlet diameters must be the same size. The water sepa­rator should be installed directly above the muffler to maintain a vertical lift. The through-hull fitting for the drain hose should be below the load water line and must have a sea cock. An EXHAUST WATER SEP­ARATOR BACKFLOW TEST must be conducted during the sea trials to determine that there is no backflow that could flood the engine.
6-1
Page 21
Exhaust Through-Hull Fitting
The exhaust through-hull fitting must be above the load water line under all anticipated uses and speeds of the boat. To reduce wave wash-in when a water separator is used (Figure 6-1), the top of the water separator must be at least 18 inches (450 mm) above the load water line. When an elbow is used at the top of the muffler outlet hose, the el­bow must be at least 12 inches (305 mm) above the through-hull fitting (Figure 6-2).
CAUTION
damage if the cylinders become flooded. The sea trials must verify that there is no backflow through either the exhaust hull fitting or the wa­ter separator drain hose fitting.
Backflow can cause major engine
EXHAUST WATER SEPARATOR
BACKFLOW TEST
Objective
To determine that there is no backflow through the exhaust water separator under any operating condi­tion (Figure 6-1).
Method
Conduct this test during the sea trials in conjunction with the RAW WATER PICKUP TEST. Prepare by closing the drain hose sea cock and disconnecting the hose from the water separator. Conduct the test by opening the sea cock while keeping the hose raised to its fitting on the water separator.
Requirement
Siphon Break
See Page 5-1.
There must not be any back flow while operating the boat throughout its speed range. If there is, relocate the through-hull fitting.
6-2
Page 22
WATER
SEA
COCK
ABOVE WATERLINE
SEPARATOR
NOT MORE THAN 6 IN (152 MM)
MUFFLER
18 IN (457 MM) MINIMUM
INSTALL A WATER SEPARATOR OR FABRI-
THE HIGHEST POINT IN EXHAUST SYSTEM
CATE A KNEE AS SHOWN IN FIGURE 6-2 AT
WATER-EXHAUST MIXER LEVEL
(SEE APPROPRIATE OUTLINE DRAWING)
LOAD WATERLINE
GENSET
54 IN (1.4 M) MAXIMUM
RECOMMEND 12 IN (305 MM)
6-3
SIPHON BREAK REQUIRED
IF LESS THAN 6 IN (152 MM)
FIGURE 6-1. TYPICAL WET EXHAUST INSTALLATION ABOVE LOAD WATERLINE—WITH WATER SEPARATOR
Notes:
1. All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).
2. The operator will not be able to look for water discharge from the hull to tell whether engine/exhaust cooling water is flowing. However, the genset will shut-
down if water stops flowing (Code No. 7) or exhaust temperature rises because of loss of water (Code No. 58). See Troubleshooting in the Operator’s Manual.
Page 23
ABOVE WATERLINE
HIGHEST POINT IN EXHAUST SYSTEM
A WATER SEPARATOR (FIGURE 6-1) AT THE
FABRICATE A KNEE AS SHOWN OR INSTALL
MIN
12 IN
(305 MM)
LOAD WATERLINE
MUFFLER
12 IN (305 MM) MINIMUM
48 IN (1.2 M) MAXIMUM
GENSET
RECOMMEND 12 IN (305 MM)
SIPHON BREAK
A SIPHON BREAK IS REQUIRED IF THE WATER-
EXHAUST MIXER IS BELOW, OR IS LESS THAN
6 IN (152 MM) ABOVE, THE LOAD WATER LINE
6-4
FIGURE 6-2. TYPICAL WET EXHAUST INSTALLATION BELOW LOAD WATERLINE—WITH SIPHON BREAK
WATER-EXHAUST MIXER LEVEL
(SEE APPROPRIATE OUTLINE DRAWING)
Notes:
1. All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).
Page 24
DRY EXHAUST SYSTEMS
Figure 6-3 shows a typical dry exhaust system. A separate exhaust system must be provided for each engine. Soot, corrosive condensate and high gas temperatures can damage idle engines served by a common exhaust system.
The exhaust system must be supported indepen­dently of the engine. Supporting the weight of ex­haust piping at the turbocharger outlet can lead to turbocharger failure.
A flexible, bellows-type stainless steel section at least 18 inches (300 mm) long must be connected at the engine exhaust outlet to take up thermal expan­sion and engine movement.
Long runs of exhaust pipe (vertical or horizontal) should include a flexible, bellows-type stainless steel section to take up thermal expansion. Flexible exhaust sections must not be used to compensate for misaligned piping or for forming bends.
Horizontal runs of exhaust piping should slope downwards from the engine to a drain trap and plug,
which should be located where the piping turns to rise vertically.
To prevent overheating that can lead to fire, route exhaust piping at least 9 inches (229 mm) away from combustible construction. Where a 9 inch (229 mm) clearance cannot be maintained, the pipe may be insulated with material rated to withstand at least 1000°F (538°C). The surface of the insulation must not exceed 160°F (71°C).
To prevent burns, shield or insulate exhaust piping and mufflers where accidental contact is likely. The surface of the shield or insulation must not exceed 200°F (93°C).
The entire exhaust system must be accessible for regular, visual inspection and repair.
See Section 10. Specifications for maximum allow­able exhaust back pressure.
CAUTION
Excessive exhaust back pressure can result in reduced power, smoke, high ex­haust temperature and reduced engine life.
RIGID
SUPPORT
FLEXIBLE
PIPE
BOW OF VESSEL
FLEXIBLE SUPPORT
RIGID
SUPPORT
MUFFLER
FLEXIBLE
SUPPORTS
CONDENSATE
DRAIN TRAP
DRY EXHAUST ELBOW
AT GENSET
FIGURE 6-3. SCHEMATIC OF TYPICAL DRY EXHAUST SYSTEM
6-5
Page 25
Page 26
7. Electrical Connections
WARNING
HAZARDOUS VOLTAGE! Touching uninsulated live parts inside the genset and connected equipment can result in severe per­sonal injury or death. For your protection, stand on a dry wooden platform or rubber insulating mat, make sure your clothing and shoes are dry, remove jewelry from your hands and use tools with insulated handles. Secure protective cov­ers when completing installation.
IMPROPER WIRING can cause fire or electric shock resulting in severe personal injury or death.
ACCIDENTAL / REMOTE STARTING of the gen­set can cause severe personal injury or death. To prevent unintended starting, do not connect the starting battery until it is time to start up the genset.
AC CONNECTIONS
Wiring Methods
All wiring methods, connections, wire ampacities, equipment grounding and materials must be in­spected and comply with applicable regulations. Use flexible conduit and stranded conductors for load wiring to take up movement and vibration.
Note: All feed-through holes in decks and bulkheads for wiring must be sealed to prevent exhaust gases and flammable vapors from entering the rest of the boat. Wiring conduit must be sealed inside as well as outside
TURN COVER SO
THAT THIS GAP IS
ON OTHER SIDE,
EXCEPT FOR
3-PHASE
CLEAR
PROTECTIVE
COVER
INSULATED
STANDOFF
TERMINALS
AC
GROUNDING
SCREW
AC
BOX
SLOTS FOR
REMOTE
CONTROL
WIRING
CONTROL
BOX
Generator (Alternator) Connections
Make generator connections or reconnections as required in the AC box (Figure 7-1) in accordance with the appropriate reconnection diagram (p. A-2). See the appropriate OUTLINE DRAWING (p. A-4 and following) regarding wiring knockout sizes and locations.
The circuit breakers may need to be replaced to ob­tain required protection or full genset power if recon­nections are made. Voltage may also need to be re­adjusted. See Section 8. Adjusting AC Output Volt-
age.
FIGURE 7-1. TYPICAL AC / CONTROL BOX
7-1
Page 27
Grounding
The genset, power supply wiring and all connected electrical equipment must be bonded to the com­mon grounding system of the boat in accordance with applicable regulations.
WARNING
equipment can lead to fire or electric shock re­sulting in severe personal injury or death.
Faulty grounding of electrical
mulation of explosive gases. Secure the battery so that it cannot shift and provide a boot over the posi­tive (+) terminal to protect against accidental con- tact.
WARNING
Arcing can ignite the explosive hy­drogen gas given off by the battery, causing se­vere personal injury. The battery compartment must be ventilated and isolated from spark-pro­ducing equipment.
Transfer Switch
Use an approved transfer switch if provision is made for connecting the boat to shore power.
WARNING
Backfeed to shore power can cause electric shock resulting in severe personal inju­ry or death and damage to equipment. Use an approved device to prevent the genset from be­ing interconnected with shore power.
Load Balancing
The electrical loads on the generator should be bal­anced as closely as possible between the AC output legs so that maximum power can be utilized from the genset. Redistribute the loads as necessary.
BATTERY CONNECTIONS
Depending on model, the genset requires nega­tive (–) ground, 12 VDC or 24 VDC for its control and cranking systems. Some models are equipped for applications requiring an isolated ground.
Battery Cables
Size battery cables according to Table 7-1. Total cable length is the sum of the lengths of the positive (+) and negative (–) cables. In other words, total cable length will be approximately twice the dis­tance between the battery and the genset.
TABLE 7-1. BATTERY CABLE SIZES
TOTAL CABLE LENGTH,
FEET (METERS)
10 (3) 4
14 (4.3) 3
18 (5.5) 2
22 (6.7) 1
30 (9.1) 1/0
WARNING
Sparks can ignite fuel leading to se­vere personal injury or death. Do not run battery cables and fuel lines together. Separate cables and fuel lines with conduit or tubing if run through the same opening. Do not tie together.
CABLE SIZE,
AWG
Batteries
See Section 10. Specifications for recommended battery capacity.
Battery Recharging
See Section 10. Specifications for the battery charg- ing capacity of the engine-driven battery charging alternator.
Battery Location and Mounting
Locate the battery where spills and leaks will not drip acid on fuel lines, wiring or other equipment and where ventilation is adequate to prevent the accu-
See the appropriate OUTLINE DRAWING (p. A-4 and following) regarding the battery cable terminal locations. Provide an insulating boot over the posi­tive (+) terminal to protect against accidental con- tact.
GENSET GROUND (VESSEL BOND)
The genset must be bonded to the common ground­ing system of the boat in accordance with applicable regulations. Connect the bonding cable to the grounding lug beside the battery cable terminals.
WARNING
Faulty bonding of the genset to the common grounding system of the boat can re­sult in severe personal injury or death.
7-2
Page 28
REMOTE CONTROL CONNECTOR
Connector J4 for remote control connections is stowed inside the control box (p. A-1). It mates with a Deutsch Part Number DT06–08S sealed 8-pin connector plug.
necting e-Series Digital Displays and/or remote switch panels. “Y” harnesses are also available for applications requiring more than one remote control station.
Non-Onan Harnesses: Use 16 AWG wiring.
Note: The connector designated J44 is for remote connections when the optional Network Interface Module (NIM) is mounted inside the genset control box. The connector designated J34 is for remote connections when the e-Series Digital Display is mounted on the genset control box. See Page A-3 for connections.
Onan e-Series Digital Displays
Up to three (3) Onan e-Series Digital Displays may be connected for remote control and monitoring of the genset. Follow the installation instructions in the kit.
A kit is also available to replace the genset control switch panel with an e-Series Digital Display panel.
Remote Control Switch and Meter
Onan Remote Control Panel Kit: Remote control panels with a control switch or control switch and hour meter are available as kits. Follow the installa­tion instructions in the kit.
Non-Onan Remote Control Panels: Refer to the wiring diagrams on Page A-3 to select and connect the remote control panel components. The Start­Stop switch must be momentary contact in both positions.
Remote Control Wiring Harnesses
Onan Harnesses: Eight-conductor plug-in wiring harnesses of various length are available for con-
Note 1: All feed-through holes in decks and bulk­heads for wiring must be sealed to prevent exhaust gases and flammable vapors from entering the rest of the boat. Wiring conduit must be sealed inside as well as outside.
Note 2: Do not route remote control wiring near AC wiring. AC can induce false signals that can cause er­ratic operation of the genset.
EXTERNAL CUSTOMER CONNECTIONS
The genset control box has factory jumpered leads with quick-connect terminals labeled SWB+, ESTOP and CO for connecting external genset shutdown devices. See the wiring diagram on Page A-1. Connect ESTOP to an emergency shut down system, such as for fire suppression, and CO to a CO detector. Leave the factory jumper connected if an external connection is not made, otherwise the genset cannot run.
The e-Series Digital Display will display Code
No. 5—SHUTDOWN DUE TO VESSEL CO or Code No. 61—EXTERNAL SHUTDOWN if shut-
down occurs. See Troubleshooting (Operator’s Manual).
Models with Option H647 (p. A-1) have a relay and connector (J14/P14) for connection to the external customer circuits. Leave connector P14 connected if an external connection is not made, otherwise the genset cannot run.
7-3
Page 29
OPTIONAL NETWORK INTERFACE
MODULE (NIM)
The optional NIM board is mounted on the wall in­side the control box. See Page A-3 for connections. It has an open 12-Pin connector socket for external network connections that mates with a Deutsch Part Number DT06–12S sealed 12-pin connector plug.
Note 1: For SAE 1939 applications see your Onan dis­tributor for more information. Onan Publication D-3315, Supported Messages on SAE J1939, must be used in designing the interface for monitoring gen­set status and diagnostics.
Note 2: For SmartCraftt applications see your Cum- mins MerCruiser Distributor for more information.
The NIM board has five jumpers to configure the board for the specific application (Figure 7-2).
1. Jumper W1 has no function at this time.
2. Jumper W2 will be cut when the genset is or- dered for an SAE J1939 network application. The jumper must remain uncut when the gen­set is ordered for a SmartCraft network applica­tion.
3. For J1939 applications jumpers W3 and W4 are used to assign the network addresses of the gensets in a multiple-genset installation. To as­sign an address, cut the jumpers as scheduled in Table 7-2.
FIGURE 7-2. NETWORK INTERFACE MODULE
CONFIGURATION JUMPERS
For SmartCraft applications see your Cummins MerCruiser Distributor.
TABLE 7-2. J1939 ADDRESSES
JUMPER W3 JUMPER W4 ADDRESS
Not Cut Not Cut 234 Not Cut Cut 158
Cut Not Cut 179 Cut cut 203
4. Cut Jumper W5 if the bus termination resistor on this NIM board is not required to terminate the network bus.
SmartCraft is a trademark of the Brunswick Corporation.
7-4
Page 30
8. Reconfiguring Voltage and Frequency
The genset was set up and adjusted at the factory for the frequency and voltage stated in the “As Manufactured” block on the nameplate (Fig­ure 8-1). If it is necessary to reconfigure voltage and/or frequency for the application, follow the in­structions in this section.
RECONNECTION LABEL
The bag in which this manual was shipped has a sheet with peel-off reconnection labels (Figure 8-2) to apply over the “As Manufactured” block on the genset nameplate (Figure 8-1) when reconfiguring the genset for the application. Apply the appropriate label if different from the “As Manufactured” data block.
FIGURE 8-1. “AS MANUFACTURED” BLOCK ON
NAMEPLATE
CHANGING FREQUENCY
The genset control box has jumper leads marked HZ SEL and 60 HZ.
1. Connect for 60 HZ: disconnect for 50 HZ.
2. Apply the appropriate reconfiguration label.
RECONNECTING GENERATOR
If necessary:
1. Reconnect the generator for the application voltage in accordance with the appropriate generator connection schematic on Page A-2.
2. Apply the appropriate reconfiguration label.
3. Adjust voltage, if necessary. See ADJUSTING VOLTAGE (p. 8-2).
Note: It may be necessary to change circuit breakers to provide required protection or full genset power when reconnecting the generator.
FIGURE 8-2. TYPICAL RECONNECTION LABELS
8-1
Page 31
ADJUSTING VOLTAGE USING OPTIONAL
DIGITAL DISPLAY
Note: The GEN STATUS screen will not display AC Voltage while the genset is in voltage adjust mode. The line for displaying the voltage is filled in as shown in Figure 8-3. A separate voltmeter is required for voltage adjustment.
1. Start the genset and let voltage and frequency stabilize for 5 to 10 seconds. Make sure all loads have been disconnected.
2. Rapidly press START 6 times during the first minute after startup to put the genset controller into voltage adjust mode. The green status lamp will blink rapidly and the Display will indi­cate a Status change from Running to Volt Adj (Figure 8-3).
3. To adjust voltage up, press and quickly re- lease START. Voltage will increase approxi- mately 0.6 volts each press and release.
4. To adjust voltage down, press and hold START for about 1 second. Voltage will de­crease approximately 0.6 volts each press and release.
Volt Adj
FIGURE 8-3. VOLTAGE ADJUSTMENT SCREEN
ADJUSTING VOLTAGE USING CONTROL
SWITCH
1. Start the genset and let voltage and frequency stabilize for 5 to 10 seconds. Make sure all loads have been disconnected.
2. Rapidly press START 6 times during the first minute after startup to put the genset controller into voltage adjust mode. The amber status lamp will begin blinking about once every sec­ond to indicate the change to voltage adjust mode. The green status lamp will remain on.
3. To adjust voltage up, press and quickly re- lease START. Voltage will increase approxi- mately 0.6 volts each press and release.
5. When satisfied with the adjustment, wait about 20 seconds for the Display to indicate a Status change from Volt Adj to Running and then press STOP to stop the genset and save the adjustment.
6. Restart the genset and check voltage.
7. Recalibrate AC Voltage on the Digital Display as instructed in the Operator’s Manual.
4. To adjust voltage down, press and hold START for about 1 second. Voltage will de­crease approximately 0.6 volts each press and release.
5. When satisfied with the adjustment, wait about 20 seconds for the amber lamp to stop blinking and then press STOP to stop the genset and save the adjustment.
6. Restart the genset and check voltage.
8-2
Page 32
9. Installation Review and Startup
Before starting the genset, review the installation checklist below for those items that do not require the genset to be actually running. Make necessary reconnections, modifications and repairs. Then start and operate the genset in accordance with the Operator’s Manual, observing all of its instructions and precautions. Continue working through the installation checklist with the genset running, mak­ing necessary reconnections, modifications and re­pairs. Check off () each item that can be answered positively. Do not place the genset in service until each item has been checked off.
The RAW WATER PICKUP TEST was con­ducted during the sea trials to establish the wa­ter line and a siphon break was installed, if found necessary.
The sea trials established that there is no back­flow through the exhaust through-hull fitting or water separator drain hose when the boat is un­der way, forward or reverse.
Genset compartment ventilation meets regula­tions and the sea trials established that ventila­tion is sufficient to maintain acceptable genset compartment temperatures, even while “heat soaking” after returning and docking.
All grounded cranking motor circuits are con­nected by properly sized common bonding conductors.
If required, the kit for isolated DC ground was installed.
An approved transfer switch prevents intercon­nections between shore power and genset.
AC wiring methods, materials and bonding for grounding meet regulations.
A properly sized battery has been installed, ser­viced and charged. The battery is securely mounted in an adequately ventilated space and the positive (+) terminal is shielded from acci­dental contact.
Remote e-Series Digital Displays and control switches function as intended.
Emergency and/or CO detection and shutdown devices have been connected and have been tested to determine that the genset shuts down as intended.
The genset is properly sized for the application, the voltage and frequency are correct and the loads across a multi-phase generator are bal­anced.
The living quarters are sealed against leaks from spaces where exhaust and fuel vapors can accumulate.
The genset is securely mounted.
There is adequate clearance for conducting all maintenance specified in the Operator’s Manu­al.
The coolant recovery tank is mounted properly and is accessible for inspection and filling.
The entire exhaust system is accessible for in­spection and replacement.
Fuel tanks, piping, hoses and filters comply with regulations and are accessible for inspec­tion and replacement.
The genset is bonded to the boat grounding system in accordance with regulations.
Exhaust back pressure is acceptable.
The exhaust system is leak-free and conveys all engine exhaust outside, away from win­dows, doors and vents.
The fuel supply system is leak-free.
The engine coolant and raw water systems are leak-free.
The engine has the proper levels of oil and cool­ant.
The raw water pump has been primed and the sea cock is open.
All operators have been thoroughly briefed on the Operator’s Manual and its safety precau­tions—especially concerning the dangers of Carbon Monoxide—and can demonstrate how to operate, maintain and troubleshoot the gen­set as explained therein.
9-1
Page 33
Page 34
10. Specifications
MDKBK MDKBL MDKBM MDKBN
ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.
FUEL CONSUMPTION:
60 Hz: Full Load
50 Hz: Full Load
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing
Model D1105 D1105 V1305 V1505
Number of Cylinders 3 3 4 4
Displacement 68.58 in3 (1124 cm3) 68.58 in3 (1124 cm3) 81.47 in3 (1335 cm3) 91.44 in3 (1499 cm3)
Bore 3.07 in (78 mm) 3.07 in (78 mm) 2.99 in (76 mm) 3.07 in (78 mm)
Stroke 3.09 in (78.4 mm) 3.09 in (78.4 mm) 2.90 in (73.6 mm) 3.09 in (78.4 mm)
Compression Ratio 22:1 22:1 22:1 22:1
Firing Order (Clockwise Rotation) 1-2-3 1-2-3 1-2-4-3 1-2-4-3 Fuel Injection Timing 16.5° BTDC 16.5° BTDC 16.5° BTDC 16.5° BTDC
Valve Lash (cold)
Lube Oil Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 4.5 quart (4.3 liter) 4.5 quart (4.3 liter)
Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPT
Coolant Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 5.3 quart (5.0 liter) 5.3 quart (5.0 liter)
Coolant Flow Rate: 60 Hz
Raw Water Flow Rate: 60 Hz
Combustion Air Flow: 60 Hz
Heat Rejection to Ambient: 60 Hz
CONNECTIONS:
Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)
Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female
Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female
Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)
Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose
Dry Exhaust Outlet 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
KEEL COOLING:
Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)
Heat Rejection to Coolant: 60 Hz
Thermostat Opening Temperature 185° F (85° C) 185° F (85° C) 185° F (85° C) 185° F (85° C)
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts* 12 volts* 12 volts* Min CCA Rating – SAE @ 32° F (0° C) 360 amps 360 amps 500 amps 500 amps
Battery Charging @ 12/24 VDC 5/10 amps 5/10 amps 5/10 amps 5/10 amps
SIZE, WEIGHT, NOISE:
Without Enclosure
Dry Weight Dimensions: L x W x H
With Enclosure
Noise Dry Weight Dimensions: L x W x H
* - 24 volts optional
Half Load
Half Load
50 Hz
50 Hz
50 Hz
50 Hz
50 Hz
0.8 gph (3.0 liter/hr)
0.5 gph (1.9 liter/hr)
0.7 gph (2.7 liter/hr)
0.4 gph (1.5 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
5.0 gpm (18.9 liter/min)
4.2 gpm (15.9 liter/min)
6.0 gpm (22.7 liter/min)
5.0 gpm (18.9 liter/min) 30 cfm (0.85 m3/min)
25 cfm (0.71 m
200 Btu/min (50 kcal/min) 179 Btu/min (45 kcal/min)
950 Btu/min (239 kcal/min) 780 Btu/min (197 kcal/min)
525 lbs (238 kg)
32.4 x 18.9 x 22.1 in
(479.1 x 822.6 x 560.9 mm)
3
/min)
66/65 dB(A) @ 60/50HZ
0.8 gph (3.0 liter/hr)
0.5 gph (1.9 liter/hr)
0.7 gph (2.7 liter/hr)
0.4 gph (1.5 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
5.0 gpm (18.9 liter/min)
4.2 gpm (15.9 liter/min)
6.0 gpm (22.7 liter/min)
5.0 gpm (18.9 liter/min) 30 cfm (0.85 m3/min)
25 cfm (0.71 m
200 Btu/min (50 kcal/min) 179 Btu/min (45 kcal/min)
950 Btu/min (239 kcal/min) 780 Btu/min (197 kcal/min)
555 lbs (252 kg)
35.9 x 22.3 x 23.0 in
(911 x 566 x 585 mm)
600 lbs (272 kg)
35.9 x 22.3 x 23.4 in
(911 x 566 x 593 mm)
3
/min)
1.0 gph (3.8 liter/hr)
0.6 gph (2.3 liter/hr)
0.8 gph (3.0 liter/hr)
0.5 gph (1.9 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
5.0 gpm (18.9 liter/min)
4.2 gpm (15.9 liter/min)
6.0 gpm (22.7 liter/min)
5.0 gpm (18.9 liter/min) 36 cfm (1.02 m3/min)
30 cfm (0.85 m
230 Btu/min (58 kcal/min) 190 Btu/min (48 kcal/min)
1220 Btu/min (307 kcal/min)
980 Btu/min (247 kcal/min)
640 lbs (290 kg)
40.7 x 22.3 x 23.0 in
(1033 x 566 x 585 mm)
66/65 dB(A) @ 60/50HZ
695 lbs (315 kg)
40.7 x 22.3 x 23.4 in
(1033 x 566 x 593 mm)
3
/min))
1.2 gph (4.5 liter/hr)
0.7 gph (2.7 liter/hr)
0.9 gph (3.4 liter/hr)
0.5 gph (1.9 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
5.0 gpm (18.9liter/min)
4.2 gpm (15.9 liter/min)
6.0 gpm (22.7 liter/min)
5.0 gpm (18.9 liter/min) 41 cfm (1.16 m3/min)
34 cfm (0.96 m
280 Btu/min (71 kcal/min) 210 Btu/min (53 kcal/min)
1420 Btu/min (358 kcal/min) 1160 Btu/min (292 kcal/min)
640 lbs (290 kg)
40.7 x 22.3 x 23.0 in
(1033 x 566 x 585 mm)
66/65 dB(A) @ 60/50HZ
695 lbs (315 kg)
40.7 x 22.3 x 23.4 in
(1033 x 566 x 593 mm)
3
/min)
10-1
Page 35
MDKBP MDKBR MDKBS
ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.
FUEL CONSUMPTION:
60 Hz: Full Load
50 Hz: Full Load
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing
Model V1903B V2203B V2803B
Number of Cylinders 4 4 5
Displacement 113.37 in3 (1857 cm3) 134.07 in3 (2197cm3) 167.57 in3 (2748 cm3)
Bore 3.15 in (80 mm) 3.43 in (87 mm) 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm) 3.64 in (92.4 mm) 3.64 in (92.4 mm)
Compression Ratio 23:1 23:1 23:1
Firing Order (Clockwise Rotation) 1-3-4-2 1-3-4-2 1-3-5-4-2 Fuel Injection Timing 14.5° BTDC 16° BTDC 16° BTDC
Valve Lash (cold)
Lube Oil Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 12.7 quart (12 liter)
Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT
Coolant Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 8 quart (7.6 liter)
Coolant Flow Rate: 60 Hz
Raw Water Flow Rate: 60 Hz
Combustion Air Flow: 60 Hz
Heat Rejection to Ambient: 60 Hz
CONNECTIONS:
Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)
Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female
Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female
Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)
Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose
Dry Exhaust Outlet 1-1/2 NPT 1-1/2 NPT 1-1/2 NPT
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
KEEL COOLING:
Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)
Heat Rejection to Coolant: 60 Hz
Thermostat Opening Temperature 185° F (85° C) 185° F (85° C) 185° F (85° C)
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts* 12 volts* Min CCA Rating – SAE @ 32° F (0° C) 500 amps 625 amps 625 amps
Battery Charging @ 12/24 VDC 40/20 amps 40/20 amps 40/20 amps
SIZE, WEIGHT, NOISE:
Without Enclosure
Dry Weight Dimensions: L x W x H
With Enclosure
Noise Dry Weight Dimensions: L x W x H
* - 24 volts optional
Half Load
Half Load
50 Hz
50 Hz
50 Hz
50 Hz
50 Hz
1.3 gph (4.9 liter/hr)
0.8 gph (3.0 liter/hr)
1.1 gph (4.2 liter/hr)
0.7 gph (2.7 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
14.0 gpm (53.0 liter/min)
10.0 gpm (37.9 liter/min)
9.0 gpm (34.1 liter/min)
7.0 gpm (26.5 liter/min)
52 cfm (1.45 m3/min) 42 cfm (1.21 m
350 Btu/min (88 kcal/min) 285 Btu/min (72 kcal/min)
1590 Btu/min (402 kcal/min) 1500 Btu/min (379 kcal/min)
830 lbs (377 kg)
44.4 x 23.7 x 26.1 in
(1127 x 602 x 663 mm)
67/64 dB(A) @ 60/50 HZ
890 lbs (404 kg)
44.4 x 23.7 x 27.5 in
(1127 x 602 x 698 mm)
3
/min)
1.9 gph (7.2 liter/hr)
1.1 gph (4.2 liter/hr)
1.6 gph (6.1 liter/hr)
0.9 gph (3.4 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
14.0 gpm (53.0 liter/min)
10.0 gpm (37.9 liter/min))
9.0 gpm (34.1 liter/min)
7.0 gpm (26.5 liter/min)
60 cfm (1.72 m3/min)
50 cfm (1.43 m
420 Btu/min (106 kcal/min)
350 Btu/min (88 kcal/min)
1980 Btu/min (500 kcal/min) 1670 Btu/min (422 kcal/min)
870 lbs (375 kg)
44.4 x 23.7 x 26.1 in
(1127 x 602 x 663 mm)
67/64 dB(A) @ 60/50 HZ
930 lbs (422 kg)
44.4 x 23.7 x 27.5 in
(1127 x 602 x 698 mm)
3
/min))
2.5 gph (9.5 liter/hr)
1.5 gph (5.7 liter/hr)
2.1 gph (8.0 liter/hr)
1.3 gph (4.9 liter/hr)
0.0071 – 0.0087 in (0.18 – 0.22 mm)
14.0 gpm (53.0 liter/min)
10.0 gpm (37.9 liter/min)
9.0 gpm (34.1 liter/min)
7.0 gpm (26.5 liter/min)
75 cfm (2.12 m3/min) 63 cfm (1.78 m
530 Btu/min (134 kcal/min) 450 Btu/min (114 kcal/min)
2490 Btu/min (629 kcal/min) 2090 Btu/min (528 kcal/min)
1090 lbs (494 kg)
53.5 x 23.7 x 28.8 in
(1358 x 602 x 732 mm)
68/67 dB(A) @ 60/50 HZ
1175 lbs (533 kg)
53.5 x 23.7 x 30.0 in
(1358 x 602 x 763 mm)
3
/min)
10-2
Page 36
A-1
630-2694
WIRING DIAGRAM (SHEET 1)
Page 37
A-2
630-2694
WIRING DIAGRAM (SHEET 2)
Page 38
A-3
630-2694
WIRING DIAGRAM (SHEET 3)
Page 39
A-4
0500-4199
OUTLINE DRAWING—MDKBL (SHEET 1)
Page 40
A-5
0500-4199
OUTLINE DRAWING—MDKBL (SHEET 2)
Page 41
A-6
0500-4200
OUTLINE DRAWING—MDKBM, MDKBN (SHEET 1)
Page 42
A-7
0500-4200
OUTLINE DRAWING—MDKBM, MDKBN (SHEET 2)
Page 43
A-8
0500-4201
OUTLINE DRAWING—MDKBP, MDKBR (SHEET 1)
Page 44
A-9
0500-4201
OUTLINE DRAWING—MDKBP, MDKBR (SHEET 2)
Page 45
A-10
0500-4201
OUTLINE DRAWING—MDKBP, MDKBR (SHEET 3)
Page 46
A-11
0500-4202
OUTLINE DRAWING—MDKBS (SHEET 1)
Page 47
A-12
0500-4202
OUTLINE DRAWING—MDKBS (SHEET 2)
Page 48
A-13
0500-4202
OUTLINE DRAWING—MDKBS (SHEET 3)
Page 49
A-14
OUTLINE DRAWING—MDKBK (SHEET 1)
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