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
Page 7
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
Page 8
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
Page 9
Page 10
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
Page 11
Page 12
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
Page 13
Page 14
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
Page 15
Page 16
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
Page 17
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.
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 inletdiameters 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.
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.
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
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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
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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 W3JUMPER W4ADDRESS
Not CutNot Cut234
Not CutCut158
CutNot Cut179
Cutcut203
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
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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 firstminute 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 holdSTART 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 firstminute 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 holdSTART 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
MDKBKMDKBLMDKBMMDKBN
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