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

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.

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii

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.

iii

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

iv

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

1-1

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.

2-1

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.

3-1

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.

4-1

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

5-1

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

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

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

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

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

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.

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).

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

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

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

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

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

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

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

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

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

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

A-1

630-2694

WIRING DIAGRAM (SHEET 1)

A-2

630-2694

WIRING DIAGRAM (SHEET 2)

A-3

630-2694

WIRING DIAGRAM (SHEET 3)

A-4

0500-4199

OUTLINE DRAWING—MDKBL (SHEET 1)

A-5

0500-4199

OUTLINE DRAWING—MDKBL (SHEET 2)

A-6

0500-4200

OUTLINE DRAWING—MDKBM, MDKBN (SHEET 1)

A-7

0500-4200

OUTLINE DRAWING—MDKBM, MDKBN (SHEET 2)

A-8

0500-4201

OUTLINE DRAWING—MDKBP, MDKBR (SHEET 1)

A-9

0500-4201

OUTLINE DRAWING—MDKBP, MDKBR (SHEET 2)

A-10

0500-4201

OUTLINE DRAWING—MDKBP, MDKBR (SHEET 3)

A-11

0500-4202

OUTLINE DRAWING—MDKBS (SHEET 1)

A-12

0500-4202

OUTLINE DRAWING—MDKBS (SHEET 2)

A-13

0500-4202

OUTLINE DRAWING—MDKBS (SHEET 3)

A-14

OUTLINE DRAWING—MDKBK (SHEET 1)