Onan Ensign 4500, Ensign 6500 Installation Manual

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MCE

Ensign

Series

4500/6500

Printed

in

U.S.A.

927-0600

8-93

Safetv

Precautions

Before

operating

the

generator

set,

read the Operator's

Manualand become familiarwithitand your

unit.

Safe

andeffl-

cient operation

can

be

achieved only

if

the

unit

is

properly

operated

and

maintained.

Many accidents are caused

byfail-

ure

to

follow

fundamental

mles

and

precautions.

Thruugkout

this

manual you

will

notice symbolswhich alert

you

to

potenliaHy

dangerous conditions

to

the operator, service

per-

sonnel,

or

the

equipment

itself.

.

l'

This

symbd warns

of

immediate

haz-

ards which

wiil

result in

severe

personal

fnjury

or

death,

EWARtMG,

This

symbol

refers to a hazard or unsafe

practice which can resuit in severe personal injury

or

death.

l%~cAu-tror\l

Thls

symbol

refers

to

a

hazard

or

unsafe

practh?

which can result in personal Injuv

or

prod-

oct

or

property

damage.

FUEL,

ENGINE

OIL,

AND

FUMES

ARE

FLAMMABLE

AND

TOXIC.

Fire,

explosion, and personal injury can result from

im-

proper practices.

Benzene and lead, found

in

some gasoline,

have

been

identified

by

some state and federal agencies

as

causing

cancer

Or

reproductive toxicity. When checking, draining

or adding gasoline, take care not

to

ingest, breathe the

fumchs,

or

contact gasoline.

Used

engine

oils

have

been identified

by

some state or

federal

agencies

as

causing cancgr

or

reproductive toxic-

ity.

When

checkingor changing engine

oil,

take

care

not

to

ingest,

breathe

the

fumes,

or

contact used oil.

Do

not

fill

fueltankswith the engine

running.

Do

not smoke

around

the

generator set area. Wipe up

any

oil or gas

spills.

Do

not

leave

oily

rags

in

engine compartment or on

the

generator

set.

Keep

this

and surrounding area clean.

InsprxAfuel

system

before each operation and periodically

while

running.

Equip the engine

fuel

supply

with

a

positive fuel shutoff.

Always

disconnect

the

battery

ground

(-)

lead

first

and

re-

conmct

it

last. Make

sure

you connect

the

batlery

cor-

rectly.

A

direct short across the battery terminals

can

CPUSCI

an explosion.

Do

not smoke while servicing batter-

ies.

Hydrogen gas given

off

during charging

is

very

explo-

sive.

Keep a fire extinguisher available

in

or near the engine

cornpa-tment and

in

other areas throughout

tke

vessel.

Use the correct

ex?inguisher

for the area. For most

types

of

fires,

an

extinguisher rated

AB6

by

the

NFPA

is

avail-

able

ancl

suitable for

use

on

all

types

of

fires except alco-

hol.

EXHAUST

GASES

ARE

DEADLY

e

Provide adequate ventilation. Equipthe bilge

with

a

power

exhauster.

Be

sure propuhion

and

generator set engine exhaust

zys-

terns are

free

of

leaks. Perform

thorough,

pcriodrc

in:pec-

tions

of

the

exhaust

system

and

repair

leaks immedistsly.

E:<haust

gases

are deadly.

Never sleep

in

the

vessel

with

the

generator

set

running

unless

the

vessel

is

equipped

with

an operating carbon

monoxide detector.

,

HOT

COOLANT

CAN

CAUSE

SEVERE

PERSONAL

INJURY

Hot

coolant

is

under pressure.

Do

not

loossn

the

coolant

pressure

cap

while

the engine

is

hot.

Let

the

engina

coal

before

opening

the

pressure cap.

MOVING

PARTS

CAN

CAUSE SEVERE

PERSONAL

INJURY

OR

DEATH

Do

not

remove

any

belt guards or covers

with

the

genm-

tor set

running.

Keep hands and

loose

clothing away from moving

parts.

Do

not

wear jewelry while servicing

any

part

of

the

genera-

tor

set.

Never step

on

the gsnerator set (aswhen entering

or

leav-

ing

the engine compartment).

It

can stress and break

unit

components, possible resulting

in

dangerous operating

conditions.

.

from

leaking

fud,

leaking exhaust fumes,

etc.

Before performing any maintenance on the gerierator

cet,

disconnect

its

batteries to prevent accidental starting.

do

not disconnect or connect battery

cables

if

fuel vapors

are

present. Ventilate the generator

set

compartment or

bilge

thoroughly

with

the power exhauster.

ELECTRICAL

SHOCK WILL

CAUSE SEVERE

PERSONAL

INJURY

OR

BEATH

Do

not

make adjustments

in

the

control panel

or

on

engine

with

unit

running.

High voltages

are

present.

Work

that

must

be

done

while

unit

is

running

should be done only

by

qualified

service

personnel

standing

on

dry

surfaces

to

re-

duce shock hazard.

.

DO

NOT

CONNECT

THE

GEldEFWTOR

SET

TO

THE

PUBLIC

UTILllY

OR

TO

ANY

OTHER ELECTRICAL

POWER

SYSTEM.

Etectrocuti n or damage

to

property

can occur

at

a

sita

remote

from the

boat where

line

cor

equipment repairs are being

made

if

the

st

is

connected

tothe

power

system.

An

approved

bander

switch

mu3

be

used

if

more

than

one

power source

iz

to

be

made

avail-

able

to

service the

boat.

Do

not workon thisequiprnentwhen

~enfa:llyor

physically

fatigued,

or

after consuming

any

alcohol or

drug

that

makes

the

operation

of

equipmmt

unsafe.

bit

8

Copy

and

post

these

suggestloris

in

potential

hazard

areas

of

the

vessel.

Table

of

Contents

SECTION

TITLE

PAGE

1

.

2

.

3

.

4

.

5

.

6

.

7

.

8

.

9

.

10

.

SAFETY PRECAUTIONS

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

Inside

Front

Cover

INTRODUCTION

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

1-1

General

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

1-1

Installation Codes and Safety Recommendations

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

1-1

Generator

Details

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

2-1

Engine Details

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

2-1

Location

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

3-1

Mounting

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

3-1

General

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

4-1

Requirements

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

4-1

Coast

Guard

and

NFPA

Requirements

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

4-1

General

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

5-1

Heat Exchanger Cooling

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

5-1

SPECIFICATIONS

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

2-1

LOCATION AND MOUNTING

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

3-1

VENTILATION

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

4-1

COOLING SYSTEM

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

5-1

Sea Water Cooling

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

5.3

Combined Cooling Systems

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

5.3

EXHAUST SYSTEM

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

6.1

General

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

6.

1

Below Load Waterline

Installation

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

6-3

Above

Load Waterline Installation

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

6-4

FUELSYSTEM

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

7.1

General

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

7-1

Installation

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

7.1

Fuelianks

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

7.2

Fuel tines

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

7.3

SiphonProtection

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

7-3

FuelSystemTest

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

7-3

ELECTRICAL SYSTEM

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

8-1

General

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

8-1

Load

Connections

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

8-1

Remote

Starting

Controls

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

8-4

Batteries

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

8-4

Installation

Checks

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

9.1

Initial Starting

and Checks

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

9-1

FINAL INSTALLATION CHECKS

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

9.1

DC

WIRING

DIAGRAM

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

10-1

i

Section

1.

Introduction

GENERAL

Each marine generator set must be installed properly

if

it

is

to

operate reliably, quietly, and most important

-

safely. Therefore, read this entire manual before starting the installation. The manual should be used only as a guide as each installation must be considered on an individual basis. For operation and maintenance procedures, refer to the MCE Operator‘s Manual

927-0124

which accompanies each unit

Proper installation is very important Requirements to

consider should include:

Adequate cooling air

a

Adequate combustion air

a

Discharge

of

exhaust gases

a

Discharge

of

circulated air Electrical connections and bonding Fuel connections Sea water connections

a

Accessibility for operation and servicing

a

Level mounting surface

a

Adequate support under mounting points

a

Noise levels

INSTALLATION

CODES AND SAFETY

RECOMMENDATIONS

The insthation must follow recommendations of the American Boat and Yacht Council (ABYC) and the National Fire Protection Association (NFPA).

The installer should be familiar with and follow the appropriate guidance found in the following publications:

ABYC

“Safety

Standards

for

Small

Craft”from:

ABYC

15

East

26th

St

New York, NY

10010

NFPA302

“Fire

Protection

Standard

for

Motor

Craif”from:

NFPA

470

Atlantic Avenue

Boston, MA

02210

USCG 33CFR183 from:

U.S.

Government Printing Office

Washington, D.C.

20404

~AWARNING

1

INCORRECT SERVICE

OR

REPLACEMENT OF PARTS CAN RESULT IN SEVERE

PERSONAL INJURY, DEATH, AND/OR EQUIPMENT DAMAGE. SERVICE PER-

SONNEL MUST BE QUALIFIED TO PERFORM ELECTRICAL AND/OR MECHANI-

CAL SERVICE.

1

=I

Section

2.

Specifications

GENERATOR

Type

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

Revolving Field, 4-Pole, Self-Excited

Standby Ratings:

60 Hertz, 6.5 MCE

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

6.5

kW, (6.5 kVA

@

1.0

PF)

60 Hertz, 4.5 MCE

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

4.5 kW, (4.5 kVA

@

1.0

PF)

50

Hertz,

5.0

MCE

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

5.0

kW,

(5.0

kVA @ 1.0 PF)

AC Voltage Regulation

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

+5%

Frequency Regulation

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

.5%

(3 Hertz)

ENGINE

Engine Type

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

Onan@ MCE, 2-Cylinder Opposed

Engine Speed (r/min)

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

I800/1500

Exhaust Outlet Hose Size

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

.2.0 in. (50.8 mm)

Fuel..

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

Unleaded, 88 octane

Fuel Inlet Size..

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

.1/4-18 NPT

Fuel Consumption, Average

@

Full Load:

60 Hertz, 6.5 MCE

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

1.3 gph

(5.0

Lph)

60 Hertz, 4.5 MCE

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

1.6 gph

(6.1

Lph)

50

Hertz,

5.0

MCE

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

1.1 gph (4.2 Lph)

Fuel Inlet Size..

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

1/4-18 NPTF

Fuel Return Outlet Size

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

.1/8-27 NPT

Minimum Cold Cranking Amps

@

0°F (-18°C).

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

360

Voltage

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

12

Capacity, Heat Exchanger System..

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

.10 Quarts (9.4 L)

Heat Rejection:

60 Hertz

@

Load, Block & Exhaust Manifold..

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

800 BTU/min

50

Hertz @ Load, Block & Exhaust Manifold..

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

650 BTU/min

Heat Exchanger System, Thermostat Open

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

.2.2 gpm (8.3 L/min)

Sea Water, Heat Exchanger System

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

.3.0 gpm (1 1.4 L/min)

Sea Water Cooling System

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

-3.0

gpm

(1

1.4 L/min)

Heat Exchanger System, Thermostat Open

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

.2.2 gpm (8.3 L/min)

Sea Water, Heat Exchanger System

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

.2.5 gpm (9.5 L/min)

Sea Water Cooling System

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

.2.5 gpm (9.5 L/min)

Sea Water Pump

Dry

Lift, Maximum

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

3

ft

(0.9 m)

Total Air Required (Generator Cooling and Combustion):

60 Hertz..

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

.146 ft3/min (4.1 m3/min)

50

Hertz

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

120 cu. ft./min (3.4 m3/min

Engine Oil Capacity with Filter

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

.3 Quarts

(2.8

L)

Battery Requirements:

Cooling System:

Cooling Flow Rate, 60 Hertz:

Cooling Flow Rate,

50

Hertz:

2-1

Section

3.

Location

and

Mounting

LO

CAT1

ON

Generator set location is preferable in the same room or compartment as the propulsion engine, as this is usually a

well

ventilated area, insulated, close to the fuel supply and isthe center of electrical load distribution. However, a generator set cannot be installed in the propulsion engine compartment unless specific conditions are met.

USCG

regulation

33CFR183

pertains to gasoline fuel systems, and requires a generator set operating in a gasoline fuel environment to be “ignition protected.”

This means a set capable of operating in an explosive environment without igniting that environment. Properly installed and operated, the

MCE

generator set can

operate in an explosive environment.

Gasoline fire or explosion can result in severe personal iniury or death.

Do

not installa gasoline generator set in the same room or compartment

of

a

diesel propulsion engine or generator set. The diesel unit may not be ignifion protected and may ignite gasoline fumes. Be sure

a

gasoline generator

set

is

insfalled in its own room or compartment.

MOUNT1

NG

The floor must be flat and givesupport directly underthe genset mounting points (Figures

3-1

and

3-2).

A

one

inch

(25

mm)

clearance around the unit is required to

permit rocking on its mounts without restraint; and

4.2

inches

(106

mm) for servicing the oil filter. Additional space must be allowed for proper ventilation for cooling and combustion, as well as service access.

Also

allow

access for periodic maintenancesuch as oil fill, coolant

fill,

spark plug replacement, etc. The entire exhaust

system must be accessible

so

a periodic visual and

audible check for leakage can be made by the operator. Install

two

hold-down clamps ortwo through boltsto the drip pan on both sides of the generator set. Tighten the clamps securely to the mounting base with bolts and

flatwas hers.

Select a location that will allow adequate space on all

sides for ventilation and servicing the set, preferably on and parallel with the keel or vessel center line. Keep the generator set away from living quarters, and away from bilge splash and vapors.

3-1

2

(i

I

3

FIGURE

3-1.

DRIP

PAN

DIMENSIONS

IN

(

4.k

"i"

)

ARE

METRIC

3-2

(HEAT EXCI

SIDE

VIEW

NOTES

I

.DIMENSIONS IN

t

l

ARE

MILLIMETERS

2.DRY

WEIGHT! 335

LBS

(152

Kgl

COOLANT

FILL

iANGER

MODEL

ONLY)

C

CONNECTION

.I2

(d

HOLE(FARSIDE1

FRONl

IL

FILL

COOLANT FILL

(HEAT

EXCHANGER MODEL ONLY1

1.19

4

I

/WET

EXH!

1

’

18.04(30.2)

{

20.43

4

l518.9)

2.00

ID

HOSE 20.25

(50.8) (458.31

4.18 (106.2)

OIL

FILTER

REMOVAL

(514.3)

FIGURE

3-2.

OUTLINE DRAWINGS

3-3

Section

4.

Ventilation

GENERAL

The installation of boat ventilation systems must meet all Coast Guard and

NFPA

requirements. Establishing the

correct

air

flow quantity

is

particularly important with

small compartments under 1000 cubic feet

(28

m3), or installations in close quarters. Ventilation systems meeting Coast Guard requirements for gasoline engines in

passenger vessels (Table 4-1) will normally suffice, however special consideration must be given to compartment conditions during operation.

TABLE

4-1.

PASSENGER VESSEL

VENTILATION REQUIREMENTS

SIZE

OF

MINUTES REQUIRED

COMPARTMENT TO EXCHANGE TOTAL

Cu.

Ft.

(m3)

AIR VOLUME

Less

than

500

(14)

2

500

to

1000 (14

to

28)

1000

to

1500 (28

to

42)

1500

and

Up

(42

and

Up)

3

4

5

REQUIREMENTS

Marine generator sets must have air ventilation for three

very important reasons:

1.

To remove flammableor other harmful gases.

Coast

Guard regulations require power blowers in the generator set and propulsion engine rooms be run at least four minutes priortostarting the engineand during operation. The operator must also inspect the engine room

for

the presence

of

fuel vapors prior to starting, especially when gasoline fueled equipment is used (see text under Coast Guard and

NFPA

Requirements).

2.

To

provide engine combustion

air

and generator

cooling air.

Coast Guard regulations require power exhausters in all installations, and one blower in each exhaust duct. Exhausters must have an air capacity

1-1

/2

to 2 times the minimum generator

set total air requirements. The

MCE

generator set

requiresa total operation minimum of 146 cubic feet

per minute

(4.2

m3/min).

3.

To

control compartment temperature during

genset operation.

This will avoid overheating which can result in shutdown from vapor lock, engine and related control component damage, and power loss.

As

a general rule, the operating environment

for a gasoline genset should not be higher than

14OOF (60OC) maximum. Lower temperatures are recommended. Often an operating power blower may be required to maintain temperature when the

genset is operating, especially when the boat is not

moving.

The compartment must have air inlets and outlets to provide this air. Inlet ducts should have cowls or equivalent fittings of twice the area of the duct, larger if the opening

is

screened.

Do

not use recessed

or

flushed

inlets, or louvered transom outlets. If the gasoline fuel tank is in a separate compartment,

it

also must be ventilated.

COAST

GUARD

AND NFPA

REQUIREMENTS

Both organizations require at least

two

inlet ducts and

two

outlet ducts extending to the bilge for gasoline

generator set installations in

a

closed Compartment. When not in a closed compartment, at least one duct should be installed in the fore section of the boat and another aft. The

NFPA

recommends a vent size of at

least

two

square inches per foot

(42.3

cm2/m) of boat

beam for total inlet area and total outet area. Boats classified as pleasure vessels by the Coast Guard

must have sufficient ventilation to eliminate accumulation of flammable gases. Boats under

65

feet

(20

m) long classified as passenger vessels require ventilation be sufficient to change the compartment air within a given time interval (Table 4-1).

For passenger vessels, the Coast Guard recommends a mechanical exhausting system to meetthe requirement in Table 4-1. The exhaust blower motors should be outside the compartment.

If a gasoline fuel tank is in a separate compartment, it must be ventilated to the same requirements as the engine compartment.

4-1

Section

5.

Cooling

System

GENERAL

Throughout this manual, flotation water drawn into the boat for engine cooling iscalled sea water. Water recirculated through the engine closed system is called captive water. Thus, confusion is avoided with other generic terms describing water use.

The

two

types of marine cooling systems covered in this

manual are

heat exchanger

and

sea wafer

cooling. An

explanation

of

each system, and the advantages and disadvantages of each are covered in separate chapter headings. The heat exchanger system is ordered most often and is standard on the

MCE

generator set Sea

water cooling is an available option.

System

Plumbing

To adequately cool the generator set under all conditions, the plumbing system must be properly planned and

installed. Excess lengths of plumbing increases flow

resistance and results in reduced cooling. An air leak in the sea water intake will reduce cooling, cause corrosion, and can even destroy the neoprene impeller in the

sea

water pump. The neoprene impeller must never be run dry, and should be primed before initial start

The water line should have a minimum inside diameter of

0.75

inch

(1

9

mm). For runs over

20

feet

(5.2

m), increase

the line one pipe size for each additional

10

feet

(2.6

m) of length. Water lines can be either copper tubing or flexible hose. Be sure a length of flexible hose is used at the generator set connection to allow set movement and for noise abatement

Unless the sea water is very clean, Onan recommends a water strainer or filter to protect the sea water cooling system. See Figure

5-1.

Onan has a hull strainer (furnished with some muffler kits) that can be used with a flush through-hull fitting. The strainer (Figure

!SI),

installed with theslots parallel to the keel, helps prevent pressure or vacuum when the boat is underway. Always use a flush-type inlet with a hydrodynamic marine muffler.

The flush-fype through-hull wafer

inlef must have

an

opening at least as

lame as fhe wafer inlef line.

TO

GENERATOR

SET

RECOMMENDED

WATER

STRAINER

OR

FILTER

FLUSH

THRU-

HULL

FllllNG

STF

CROSS-SECTION

VlMl

HULL.

--WNER

CS-1312-1

FIGURE

5-1.

SEA

WATER

INLET

Stagger the generator set water inlet

so

it is not directly in

line with other inlets. Not doing

so

can reduce the amount of sea water available to the generator set when underway and cause overheating. Never use scoop type water inlet fittings with a hydrodynamic muffler.

-1

Do

not use scoop

fype

wafer inlet

fit-

tings with a hydrodynamic muifler.

Forward

facing

scoops can develop suiiicienf

rampres-

sure

to force wafer

past

the

generator

sefs

sea

wafer

pump. This can floodfhe exhausfsystemandfhe engine

cylinders. This

happens

when the generator set

is

not

running and the boat

is

underway.

Rear

iacing scoops

develop vacuum which can impede

ding

wafer flow.

HEAT EXCHANGER COOLING

This cooling system, standard on the genset, keeps sea water and the resulting sediment deposits

(salt,

silt, etc.),

from the engine cooling jacket It also provides more

uniform cooling and temperature control in the engine.

Sea water and captive water are kept separated, and the engine water jacket stays clean for optimum heat transfer.

5-1

Figure

5-2

shows the flow direction of sea water and

captive water. The sea water pump constantly renews the cool water bath in the heat exchanger and exhaust system. The captive water is circulated by a pump through the engine block, heat exchanger, and the exhaust manifold. The captive water temperature and flow rate are controlled

by

thermostats.

Each genset has a recoverytank kit to be installed in the

captive cooling system. The tank (similar to automotive application) is connected to the overflow fitting below the pressure cap. It keeps the captive system filled with coolant which helps prevent corrosion and sediment. The tankshould be locatedforeasychecking

of

coolant level, and for serviceability. lnstallation instructions are furnished with the kit.

BELT-DRIVEN

SEA

WATER PUMP HEAT EXCHANGER

r-

I

FROM

SEA

WATER INLET

The captive cooling system should always use a

50-50

mixture of ethylene glycol and distilled water to help prevent corrosion. See the

lnstallation Checkout

sec-

tion for filling instructions. If a heat exchanger other than the Onan standard is

installed, several precautions are required as follows:

The heat exchanger must properly cool thegenera-

tor set under all load conditions.The Onan system is

designed to cool the set at full load with sea water inlet temperatures up

to

1

OOOF

(38OC).

Extra margin

(10%)

must be allowed for varying conditions of

pumps, coolant and scale build up. Minimum captive water and sea water flow required

by the generator set must be met. The heat exchanger will also have minimum and maximum flow requirements which must be met for cooling at

its capacity. The generator set requirements are

listed in the

Specificafion

section.

r*

I

t

I

.-*----

t

MANIFOLD

(MIXER)

EXHAUST AND

SEA

WATER OUTLET

TO

MUFFLER

by Separate Pump

--P

Captive Cooling Water Circulated by

cs1369

....

FIGURE

5-2.

COOLANT

FLOW, HEAT EXCHANGER COOLING SYSTEM

5-2

SEA WATER

COOLING

The sea water cooling system is shown in Figure

5-3.

This

system

uses

the belt-driven

sea

water pump to direct water through the engine cooling system and out the exhaust system. The electric circulating pump

is

not used on this system. The engine blocks have a drilled coolant bypass hole to allow some coolantflow regardless of thermostat opening. This allows for exhaust cool-

ing and protection of the pump. The sea water and exhaust is disposed

of

similarly as described in Heat

Exchanger Cooling with a hydrodynamic muffler (above

or

below water line installation).

The sea water comes into direct contact with the engine cooling jacket, and this system should be avoided for

use

in salt

or

contaminated water. Such water can cause engine block corrosion and/or plugging; therefore, heat exchanger systems are recommended.

.

COMBINED

COOLING

SYSTEMS

Onan does not recommend combining the generator set cooling system with the propulsion engine cooling sys-

tem. This involves a great amount of experience and

knowledge for the installer, as well as complete knowledge

of

characteristics of both the generator set and

propulsion engines.

Propulsion engines use scoop-type water inlet fittings which must not be

used for a generator set with a hydrodynamic muffler.

When not operating, ram pressure can force waferpast

the generator set’s sea water pump and flood the exhaust system. From here it can flow back, flooding the engine cylinders and possibly the engine com-

partment.

BELT-DRIVEN

SEA

WATER

PUMP

EXHAUST

MANIFOU)

I

,-

I

EXHAUSTMANIFOLD

/I\

FROM

SEA

I

(MIXER)

/I\

+

WATER

INLET

I

re

I

EXHAUST AND

SEA

WATER OUTLET

TO

MUFFLER

I

+

I

FIGURE

5-3.

COOLANT

FLOW.

SEA

WATER

COOLING

5-3

Section

6.

Exhaust

System

GENERAL

The installation of

two

water-cooled exhaust systems are covered in this section. They are below-load waterline and above-load waterline, and are covered under separate headings.

All

exhaust systems for water-cooled marine installations must meet each of the following requirements. Failure to meet these requirements could result in severe property damage, personal injury or

death.

b

The entire exhaust system must be accessible

so

a

periodic visual and audible check for leakage can be

made by the operator.

0

The exhaust system must be water cooled, and the water injected as near to the generator set as possible.

0

All

exhaust system sections preceding the point of

water injection must be water jacketed or effectively

insulated or shielded.

0

The exhaust line must be installed to prevent back flow of water to the engine under any conditions; and the exhaust outlet must be above the load waterline.

Water backflow into the engine will damage

it

The generator set exhaust system

must

not

be com-

bined with the exhaust system of another

engine.

0

A

flexible section of marine exhaust hose must be used near the engine to allow for engine movement and vibration during operation.

All

exhaust system

hoses must be CERTIFIED for marine use.

0

The exhaust system must be of sufficient size to prevent excessive back pressure. See Back Pressure data in this section.

Install exhaust through hull fitting aft of sink, shower or other cabin drains to prevent backflow of exhaust gases into the vessel.

Material

Use material recommended by ABYC in

“Safety

Standard

for

Small

Crafi,

”Section P1. The exhaust line must be at

least as large as the engine exhaust manifold outlet

See

following section on Back Pressure.

Exhaust gas contains carbon monox-

ide, an odorless, colorless, highly

poisonous gas that presents the hazard of severe

per-

sonal injuw

or

death. Place special emphasis on the

following:

0

Be

sure

the flexible exhaust hose

is

designed and

certified

for

marine exhaust line use.

Use

two

clamps at each end

of

all flexible exhaust

hose connections.

Do

not make shatp bends in the exhaust hose.

0

Position exhaust outlet

to

prevent backflow of

Use flexible hose designed and CERTIFIED for marine exhaust line use. The muffler must be at the lowest point of the entire exhaust system. The muffler top should be at least 12 inches

(305

mm) below the exhaust manifold outlet If it is higher, backflow of water toward the manifold is more likely.

Make sure the hose drains toward the muffler at

a

grade

of

1

/2

inch per lineal foot

(42

mm/m). An uphill section between the exhaust manifold and muffler can cause backflow of water and is not permissible

-

NO

EXCEPTIONS.

exhaust gases info the vessel.

Be

sure that the vertical rise

of

the exhaust hose measured fromthe bottom of the muffler to its peak is not more than

48

inches (1.2

m)

as shown in Figure 6-1.

The exhaust tubing (on both above and below load water-

line installations) must be pitched downward to the

through-hull outletfitting ata minimum downgrade of 112

inch per lineal foot

(42

mm/m). There must also be a

12-inch

(305

mm) minimum drop from this peak to the

through-hull outlet fitting as shown in Figures 6-1 and

6-2.

Allow space between the marine muffler and

its

mounting surface by use of spacers under the mounting flanges. This allows air circulation under the muffler and discourages condensation build-up.

6-1

Usetwo clamps at each end of hoseasshown in Figures

6-1

and

6-2.

The clamps must be

Of

corrosion resistant

metal, a minimum Of% inch

(12.7

mm) wide. They should

be spaced at kist one clamp width apart, and at least one

clamp widthfromtheend ofthe hose. Clamps depending

solely on spring tension must not be used.

Provide adequate support for hose lengths to prevent sagging, bending, and fOrmation

Of

water Pockets- The

use ofautomotive@Pe Pipe hangers

Will

help stop tms-

mission of vibration or noise to the boat hull.

Back

Pressure

Exhaust back pressure is an important criteria of an a&quate exhaust system.

If

the exhaust installation requires

a long run of pipe (more than

30

feet

[9

m] overall), back pressure should be checked. Exhaust back pressure for the

MCE

generator set should not exceed

3.0

inches (76

rnm) of mercury

(10

kPa).

Increase theexhaust pipe diameter from the mufflertothe hull outlet one standard pipe size for every

10

feet

(3

m)

beyond

30

feet

(9

m) of overall length.

"\

TO GENERATOR

SET

SEA

c

RECOMMENDED FLUSH-TYPE, THROUGH-HULL FliTlNG

AND WATER STRAlNER (NOTSUPPUED

BY

ONAN)

.

FLUSH THRU-HULL Sk/VNER

CS-1312-1

FllTING

FIGURE

6-1.

BELOW

LOAD

WATERLINE

INSTAWTlON

6-2

Exhaust

Cooling

Water

Injection

The neoprene impeller pump moves the

sea

water

through the

cooling

system and into the exhaust manifold. The injected water cools the exhaust and prevents exhaust system damage from heat

A

temperature operated switch on theexhaust manifold shu tsthe unit down if overheating occurs. The switch closes if temperature reaches

175'

to

185°F

(79'

to

85'C)

and actuates the

Fault Reset breaker on the control panel.

If

high exhaust

temperature shutdown occurs, the entire exhaust system

should be checked for any signs

of

overheating, especially the exhaust hoses. Replace defective components immediately, and do not operate the generator set until

Inhalation of exhaust gas

can

cause

jawnR"Gl

severe personal

injury

or

death.

Do

not operate the generator set after a high exhaust temperature shufdown until the entire exhaust system

has been checked

and

serviced as mquimd.

.

system is repaired.

DO

NOT

USE

SCOOP

TYPE

WATER

-1

INLET FITTINGS. Forward

facing

scoops

can

develop suificient ram

pressure

to

torce

wafer

past

the

generator set's

sea

waferpump. Thiscan

flood

the

exhaust system and the engine cylinders. This

happens when the generafor set

is

not running and the

boat

is

underway. Rear facing scoops develop vacuum

which

can

impede

cooling

water flow.

BELOW

LOAD

WATERLINE

INSTALLATION

Figure

6-1

shows details

of

a

recommended below load

waterline installation. Review and apply

data

from

the

preceding

G€N€ML

section, plus the following.

Siphon

Break

Install a siphon break (anti-siphon)

if

the

sea

water injec-

tion port on

the

exhaust manifold

is

at or below

the

load

waterline. The siphon break is a vacuum operated vent valve that opens the exhaust water discharge line to the atmosphere when the engine

is

not operating. The open

vent valve prevents

sea

water (flotation water) from being siphoned into the exhaust manifold and cylinders on engines installed below load waterline.

The siphon break hoses connect between the exhaust

manifold water injection port and the water tube from the heat exchanger. Connect the siphon break hose ends to

these connectors. Remove plug from top panel and route

hoses through the hole. Locate the siphon break in a vertical position at least

12

inches

(305

mm) above the load waterline.

See

Figure

6-1.

Remote mounting is permissible within a 5 foot

(1.5

m) radius

of

the injection port The vertical position and

height of the valve must be maintained.

HIGH EXHAUST TEMPERATURE

CUTOUT,SWITCH

TWO

HANGER

MINIMUM

DOWNGRADE

112

INlLlNEAL

FT

-------------------------------------------------------

LOAD WATERLINE

FIGURE

6-2.

ABOVE

LOAD

WATERLINE

INSTALIATION

6-3

The siphon break must be mounted vertically with the threaded end pointed down. Use pipe strap material to secure the assembly to the frame or bulkhead. Be sure

the slotted opening in the siphon break valve is open to

atmospheric pressure. The valve will not function if the

slot

is closed in any way.

1-1

Failure to use a siphon break when the exhaust manifold injection port

is

at

or

below the load waterline will result in sea water

damage to the engineandpossible flooding of tbe boat.

ABOVE LOAD WATERLINE

INSTALLATION

Figure

6-2

shows detailsof a recommended above load

waterline installation.

A

siphon break valve is not required with this installation. Review and apply data from the preceding GENERALsection. Be sure the minimum drop and downward pitch of exhaust runs are applied, and that all hose end connections have

two

clamps as shown.

6-4

.

Section

7.

Fuel

System

GENERAL

Fuel leakage in boats presents fire

-1

and explosion hazards that can

result in severe personal injury

or

death.

For

this rea-

son,

it is important that the material, design, consfruction and installation of all fuel system components meet the highest possible standards. Use only products specified

for

marine application.

Make sure all fuel lines are properly supported and

connections tightened securely. Use an approved pipe joint compound acceptable for use with gasoline fuel at all thread fittings.

Fuel distribution lines must have as few connections as practicable, and be protected against mechanical injury and vibration. In all fuel system installations, cleanliness is very important. Take precautions to prevent the entrance of moisture, dirt or contaminants of any kind during installation.

If

possible, avoid the use of fuels composed of blends of gasoline and alcohol. Methanol notably can cause corrosion of metals and damage to plastic and rubber. Some blended fuels may have cosolvents in them to prevent damage, but the suitability of these fuels is not fully known at thistime. Fuel containing alcohol can also cause external paint damage

if

spilled during refueling. Some states require the use of labels on pumps to indicate alcohol content If unsure, ask the fuel station operator.

INSTALLATION

Any flexible fuel line installed between the fuel tank and the generator set must meet USCG requirement 33CFR183.558 and be stamped

“USCG

TYPEA”.

There cannot be an electrical connection between the hose end fittings. A bad ground in the cranking circuit will cause a wire reinforced hose to become hot and ignite the fuel during cranking. If a metallic fuel line is run into the generator set compartment, a length of flexible hose meeting the above specifications must be installed to absorb vibration from the generator set.

Ignition

of

fuel can cause fire and

severe personal injury or death. Be sure any flexible fuel line used between the fuel tank and the generator

set

meets

USCG

requirement

33CFR183.558

and

is

stamped

“USCG

TYPE

A”.

SERVICE

SHUT-OFF

VALVE

PROPULSION

ENGINE

GENERATOR

FUEL

TANK

FIGURE

7-1.

I

M-1679

INSTALLATION ABOVE TANK LEVEL

Leakage

of

gasoline in

or

around the

generator

set compartment presents

a hazard

of

fire

or

explosion and can cause severe

personal injury

or

death.

Do

not

permit

any flame,

spark, cigarette, pilot light, arcing equipment,

or

other ignition source near fhe generator set. The ventilation system must provide a constant flow

of

air

to

safely

expel all fuel vapors.

The fuel line should be run at

or

above level of the tank

top to a point close to the engine connection whenever

possible to prevent siphoning. See Figure 7-1.The line

should be supported throughout its length with clips

or

straps spaced at no more than 14-inch (355 mm)

intervals.

A

separate fuel line is recommended for the genset. If a fuel tank is shared, afuel linetee isnotrecommended-A tee can cause erratic set operation due to fuel starvation. The generator set’s fuel pump has neither the

capacity nor the power to overcome the draw of the propulsion engine fuel pump.

If the fuel tank fitting is large enough, a second, shorter

dip tube may be installed as shown in Figure

7-2.

The

required fittings can be built by a machine shop. Install

an anti-siphon device at the tank fitting as shown.

FUEL LINE TO

PROPULSION ANTI-SIPHON FUEL UNE TO

ENGINE DEVICE GENERATOR

SET

HEX

HEAD

CAP

FTTTING

FIGURE

7-2.

TWO

FUEL LINES IN

TANK

FllllNG

1-1679.2

If

the tank does not have an unused outlet, a new outlet can be installed. The metal tank must be removed to braze

or

weld a new outlet fitting. This procedure

.

requires the service of a welder familiar with the essen-

tial safety measures.

1-1

Ignition

of

fuel vapors can cause

severe personal injury

or

death.

Welding a

fuel

tank, empty

or

not, is extremely danger-

ous!

Vapors can ignite causing an explosion and fire.

Another consideration is the generator set fuel pump

lift

capacity. The vertical height must not exceed 4 feet

(1.2

m), minus the requirement

of

an anti-siphon valve when

used,

or

the generator set operation can be adversely

affected.

FUEL

TANKS

Avalve must be installed directly at the tank connection to shut

off

fuel flow. This valve may be electrically

or

manually operated. If electrical1,y operated, it must be energized only during engine operation, and have a manual override to comply with

USCG

regulations. This electric valve can be purchased from Onan and is listed in the parts manual.

The manual valve must have an arrangement for operating

it

outside the compartment in which the tank is

located, preferable from above deck. A USCG approved service shutoff valve must be

installed at the engine end of the fuel line under conditions listed below. This valve stops fuel flow when the genset is serviced.

0

When fueltanksare located in a compartment other

When the engine and fuel tanks are separated more

than the engine.

than

12

feet

(3.7

m).

If the propulsion engines and generator set usedifferent fuels, a separate fuel tank will be required. Use only an approved fuel tank designed

for

marine application. Be

sure thatthe Compartment is well ventilated (see

Ventila-

tion

System

section). Fuel consumption data in the

Specificafionssection is useful for determining the tank

size. When installing a separate tank, locate it as close as

possible to the generator set Compartment. Be sure it is accessible and can be removed for inspection.

Fuel starvation can cause marginal operation of the generator

set.

Fiber-

glass

fuel

tanks can present a problem if the fuel pick-

up tube is too.close

to

the tank bottom. Fiberglass

fibers can seftle and

form

a

mat

wifh

time.

Make

a

diagonal cut

on

the bottom

of

the pick-up tube and

install

35

to Pinches

(73

to

51

mm) from the fankbottom.

Mount the fuel tank and secure into position. The

NFPA

recommends that flat bottom tanks be installed on slatted wooden platforms to help prevent moisture condensation. Cylindrical tanks should be set in chocks

or

cradles and securely fastened. Small fuel tanks can be suspended from deck beams.

Support and brace the tank to prevent any movement.

Line up braces with the tank internal baffle plates. Insu-

late all wood

or

metal surfaces from the tank surface

with a non-abrasiveand nonabsorbent material. Heavy

rubber-impregnated cotton fabric or oil and acid-

resistant plastics work well.

Ignition of fuel

when

filling the tank

l&lZ@l

can result in

seuere

personal injury

or

death. All metallic fuel tanks

MUST

be

electrically

bonded to

the

boat common ground. Also bond the

filler neck

or

opening

to

the tank if a hose is used

between them. This helps prevent static spark when

filling that can ignite the fuel.

Position the tank

fill

and vent pipes

so

fuel

or

vapor

cannot escape into the bilge. Run the vent and

fill

pipes

from separate openings in the tank.

If

the

fill

pipe has a

flexible section of fuel hose, install aseparate grounding

wire between the deck fuel plate and tank. Install the

vent opening as far from any other hull opening as

possible and with a gooseneck

so

water cannot enter.

Install a flame arrester on the vent opening.

7-2

FUEL LINES

The proper installation of fuel lines is very important Give special attention to the following requirements.

0

All

fuel line materials must meetthe requirementsof

both the USCG and the ABYC.

0

Solid fuel lines must be seamless annealed, doubleflared, and approved for marine installations.

0

Run fuel lines at the top level of tank to a point as close to the engine as possible to reduce danger of fuel siphoning should the line break.

areas. This reduces chance of vapor lock.

I

.

0

Keep fuel lines away from hot engine or exhaust

0

Any locked-in torsional stresses must be avoided in

the fuel line.

0

Install a flexiblefuel line meeting USCG requirement 33CFR183.558, and stamped

“USCG

TYPE

A”

between the solid fuel line and engine to absorb vibration. The line length must be sufficient to prevent binding or stretching due to generator set movement.

,

FUEL LINE

I

TO

BOAT

I

COMMON BONDING

METALLIC

FUEL

CONDUCTOR

LINE FROM TANK

ES-1891

FIGURE 7-3. FUEL LINE BONDING

Install fuel lines

so

they

are

accessible and pro-

tected from damage.

Use non-ferrous metal straps without sharp edges

to secure the fuel lines every

14

inches

(355

mm).

Electrically bond a metallic fuel line to the vessel with a suitable bonding strap. The drip pan must also be bonded to thissame conductor asshown in Figure 7-3.

SIPHON

PROTECTION

A carburetor float valve cannot be trusted to stop fuel flow if there is gravity feed from the fuel tank. When the tank is installed above the engine level an anti-siphon device is needed to prevent

the

fuel from emptying into the carburetor if the float valve doesn’t close.

It

also prevents siphoning if the line

breaks at a point below the fuel level. Mandatory siphon protection must be provided by

installing a

U.S.

Coast Guard approved anti-siphon

device. See Figure

7-4.

This device can be installed at the tank withdrawal fitting, or at a location where the line from the fuel tank will no longer remain above the fuel tank top level. The device can be either a mechanical check valve

(1

f0.5

psi

[6.9

53.5

kPa]), or an electric valve with mechanical

override. The electricvalve must be connected

so

it

operates only when the engine ignition is on.

ANTISYPHON VALVE OR ELECTRICALLY

OPERATED FUEL STOP VALVE

M-1679

FIGURE

7-4.

SIPHON PROTECTION

FUEL SYSTEM TEST

After installation, test thefuel system fortightness by pumping air into the tank to a pressure Of

4

to 5 psi (28 to 35 kPa). Pressure must remain steady. If not, the leak must be found before putting the system into service.

7-3

.

Section

8.

Electrical

System

GENERAL

All

wiring &meet Coast Guard,

NFPA,

and

all

other applicable codes. Have all wiring installed by a qualified electrician. Onan wiring diagrams do not include components added by customers.

Faulty electrical equipment can

cause shock and severe personal

injury or

deafh.

Use

only approved power supply

the power cord. lncorrect

or

no ground may cause the

vessel to be electrically

"hot".

I

assemblies, and never remove the grounding pin from

LOAD

CONNECTIONS

While at dock, most boats have a dockside connection for use of commercial power. These installations must have a transfer switch to isolate the generator set and the commercial power. The

two

power sources never be connected together. A manual transfer switch is available from Onan for this function. See Figure

8-1.

Ignifion

of

explosive fumes can

IiEFi%I

cause severe personal injury

or

death. The load fransfer switch cannot

be

used

in

a

gasoline fueled environment unless certified

for

such

use. Separation

by

a bulkhead

or

deck is necessary.

Use a section of flexible conduit at the generator set to absorb vibration. Flexible, multistrand wire must be used throughout

to

reduce the danger

of

breakage due

to boat movement or vibration. The generator set

is

available in either 120-volt

(two-

wire) or 120/240-volt (three-wire) as shown in Figures 8-2 and

8-3.

The three-wire

(1

20/240-volt) genset must have the 120-volt loads balanced across thetwo generator windings. Taking full load from only one winding can cause damage to the generator.

A

240-volt load is

connected across both windings. The 120-volt genset will haveasingle-pole breaker; the

120/240-volt genset will have a two-pole breaker.

ONAN

SWITCH

TO BRANCH CIRCUIT

PROTECTIVE DEVICES

300-0269

2-POLE,

120

VOLT

SYSTEMS

300-0270

3-POLE,

1201240

VOLT

SYSTEMS

OBSERVE

NEGATIVE

GENERATOR

SET

GROUND

'EQUIPMENT GROUNDING CONDUCTOR '(GREEN)

L

GROUNDED NEUTRAL CONDUCTOR (WHITE)

UNGROUNDED CONDUCTOR (BLACK)

UNGROUNDED CONDUCTOR WHEN USED

(BUCK)

-

GENEGATOR

---------------

SHORE-POWER DISCONNECT

/

CIRCUIT BREAKER

FROM

DOCKSIDE

POWER SOURCE

'Equipment ground

is

not part

of

generator

wiring:

must be customer installed

if

required.

FIGURE

8-1.

TYPICAL

MANUAL

TRANSFER

SWITCH

CIRCUIT

c

I

A1

1

CB22 CR21

G21 T21

RV21

TB1,2

ROHT

PANEL

(REAR

VIEW)

PCB ASSY, ENGINE MONITOR CIRCUIT BREAKER,

LOAD

BRIDGE RECTIFIER GENERATOR, AC TRANSFORMER ASSY

SUPPRESSOR ASSY

STAND-OFF INSULATOR

CONNECTION

SEE

NOTE

2

I

RV2

I

i

.

FIGURE

8-2.

GENERATOR AC WIRING DIAGRAM

8-2

COMPONENT IDENTIFICATION

1

CRZI-AC

A1 1

CB22

cR21

621

TB1,2

RV21

T21

PCB ASSY, ENGINE MONITOR CIRCUIT BREAKER, LOAD BRIDGE RECTIFIER

.

GENERATOR, AC TRANSFORMER ASSY

SUPPRESSOR ASSY

STAND-OFF INSULATOR

x

NOMINAL NOLOADVAC

127.5?4.5

LEADS

TOMCRUSE HOYWAL

NO

VAC

x3

x4

TO

ADJUST

WlRlT

VOLTAOL,MOVE TAPSONT21

ACCDRDINB

TD

TABLES. I.IN ALL WLTAQECOmECTKmS

LEAVETIAHIT4

t.FOR6DHz:VSE?%LUDONTIPSXI-2

3.

IF

CS.22

IS

NOT

USED

CWNECr

LEADS

DlPEClLY

4.UNLESS

UlHfRWlSE

&,ALL

COMWNCMS

AESHOWN

IN

5.

MSND

LINESINC4CATEWHEN~

Lo

L2

LI

CONNECTED

TOHI

ANDIH

REspEcnvw.

(4

TApSlW

W%. [ FROM

OENl

WD

ONTAPS

x5.4

TO

%E

LOAD.

THEDE-D(CRGIZEDPOS~ON

FIGURE

8-3.

GENERATOR AC SCHEMATIC DIAGRAM

8-3

REMOTE STARTING CONTROLS

Onan has control panel kits available for remotestarting and stopping of the genset The kits vary from a basic single-pole, double-throw, momentary-on switch on up to remote-gauge controls with running time meter, battery condition meter, and engine monitors. The kits come with installation instructions and wiring diagrams for connection.

The control panels are prewired and terminate with a plug connector. See Figure 8-4. Onan has prewired harness assemblies in

15,25,

and 45 foot lengths (4.6,

7.6,

and

13.7

m) with plug connectors that connect to the generator set control boxand the remote panel. Multiple remote stations are possible with parallel hard-wiring. The genset can be started and stopped from any station, including the set itself. Engine monitor gauges can be used on only one panel (generator set or remote).

If prewired harnesses are not used, number 16-gauge

wire is acceptable if runs do not exceed

25

feet (7.6 m)

between the remote switch and the genset. Use number

14-gauge wire for longer runs.

-1

lnterchanging connections other ihan shown on the generator set wir-

ing

diagrams can cause equipment damage.

BATTERIES

General

Always use a battery at least as large as specified. The battery should be installed close to the generator set, preferably in a separate compartment The compartment must be well ventilated to preventaccumulation of explosive battery gases.

Mount the battery in an acid resistant tray on a platform above the floor. It must be secured to prevent shifting. If mounted in an engine compartment, always install a non-metallic cover to prevent battery damage and arcing from accidentally dropped tools. Figure 8-5 shows a typical battery tray and cover.

Maintenance free batteries definitely should be considered for marine application. New technology of these batteries make them completely sealed and maintenance free. They usually offer higher output

(CCA),

better durability and vibration resistance than other equally priced batteries.

PCB

ASSY

-

ENGINE

MONITOR

I

TB12

I

11"

K12

n

0

GND

1

ES-167c2

FIGURE

8-4.

REMOTE

CONTROL CONNECTIONS

ESHW

CaMeSize

Lengwl

FIGURE

8-5.

TYPICAL BAllERY TRAY

AND

COVER

Leakage of fuel in

or

around the

l3iESl

generatorset compartmentpresents

a

hazard

of

fire

or

explosion that can cause severe per-

sonal injury

or

death.

Do

not disconnect

or

connect

battety

cables if fuel

vapors

are present. Ventilate the comparfment thoroughly with the bilge blowers orpower exhausters.

2

1

0

00

0oooooO

4ft

5ft 7ft

(12

m)

(1.5

m)

(21

m)

(27

m)

(3.4171)

(4.3m)

9ft

11ft

14ft

Connectthe battery cablesasshown

in

Figure

8-6.

Use

cable sizes specified

in

Table

8-1.

Be

sure the battery

connections are clean and

tight;

then cover the battery

terminals

with

a dielectric grease

to

retard corrosion.

Connect the battery negative lead to the generator set at

the location shown

in

Figure

8-6.

Failure

to

do

so

can

cause arcing

or

resistance

in

the cranking circuit

The ignfion

of

gasoline fuel or fumes

lZEHEl

can result in severe personal injury

or

death. Connect fhe generafor set battery ground

lead only

af

the Iocation shown.

TABLE

8-1.

BAlTERY CABLE

SIZE

REQUIREMENTS

(Maximum

Length

of

One

Cable)

Eli

WASHERS

LOCKWASHER

a+-

B-

VlEWA

VIEW

B

HARDWARE

ASSEMBLY

ES-1672-2

FIGURE

8-6.

BATTERY CABLE CONNECTIONS

Grounding

Onan marine generator sets require the batteries connected negative ground. Most propulsion engines and vessel electrical equipment have negative ground systems.

BATTERY ACCEPTABLE BATTERY

+

f

7

w-

0--

The generator set and propulsion engineh must be

grounded in accordance with

USCG

regulation

33CFR183.415. The regulation requires a common ground

conductor connected between the generator set and propulsion engine cranking motor circuits. The conductor must be the same size as the largest battery cable. See Figure

8-7.

COMMON CONDUCTOR SAME

SIZE

AS BATTERY CABLE

d

\

The conductor prevents accidental passage of cranking current through the

fuel

systems and smaller electrical

conductors common to

the

engines. This can happen if

a

cranking motor ground circuit becomes resistive or opens

from corrosion, vibration, bad cable, etc.

GENERATOR SET

rmpmper

gtwnd

can cause seven?

l3BHSl

persona/ iniury

or

death

trom

fire

or

explosion.

Besun,

to

installa commongrrxrndconductor

hiween

all

on

bead

cranking

circuiis.

Do

not connect the

battery

negative

lead

to

the

generator

set at a location other than shown in Figure

8-6.

PROPULSION ENGINE

I

FIGURE

8-7.

COMMON GROUND CONDUCTOR

Bonding

The generator set must

be

bonded to

the

vessel

common bonding conductor with a bonding strap as shown in Figure 8-8.

If

a metallic fuel line

is

installed between the fuel

tank

and the generator set shutoff valve, it too must be

bonded to the same vessel common conductor.

COMMON

BONDING

CONDUCTOR

Es.1891-I

FIGURE

8-8.

BONDING CONNECTlONS

8-6

Section

9.

Final Installation

Checks

INSTALLATION

CHECKS

Before trying to start the generator set, determine that the installation is complete by answering affirmatively the following questions:

Is

the exhaust system secure and all connections

tight?

Is

a flexible section of exhaust hose used between

the genset and muffler?

Is

all exhaust hose certified for marine exhaust application, and adequately supported and protected?

Is the exhaust outlet terminated away from windows, vents or other openings that might allow exhaust gases to enter the vessel, or be pulled into the vessel when in motion?

Does the fuel system have a flexible section at the generator set to allow for.movement

of

the genset

when the vessel pitches?

0

Are the AC generator and load wires securely and

0

correctly connected to the circuit breaker? Are the battery cables connected correctly and

securely at the generator set and battery? Has crankcase oil and coolant been added to the

engine, and are they at correct levels? See the

Main-

tenance section of the Operator’s Manual.

Oil, fuel and coolant have been

drained from the engine prior

to

shipping from the factory. Operation wifhouf oil or coolant MI damage fhe engine.

INITIAL STARTING

AND

CHECKS

Refer to the Operator’s Manualbefore trying to

start

the generator set Make sure the fuel shutoff valve and sea water cock are open. Operating the sea water pump

without water will ruin the neoprene impeller.

Gasoline vapors

can

cause an explo-

sion and fire resulting in severe personal injury or death. Before starting thegenerator set, operate the bilge blower for a minimum ofrlminutes. If fuel fumes are present, locate the source and correct

prior

to

generafor

set

operation.

1.

2.

3.

4.

5.

Start the genset by holding the StartIStop switch in the Start position. The

genset

should

start

within a few seconds. If not, check fuel supply and shutoff valve/s.

Check the hull exhaust outlet for water flow and the genset operation. Monitor the remote control panel gauges (if equipped) for normal range of readings. Refer

to

Operator’s

Manual

for proper values.

Check the exhaust system for leaks, visually and audibly. Note the security of the exhaust system supports. If any leaks are found, shut down the genset immediately and repair.

Exhaust gas is deadly. For this

AWARNING

reason, shutdown fhegenerafor

set

immediatelyifan exhaust leakor exhaustcom-

ponent needs repair.

Do

not

run

the generator set

until the exhaust system is repaired.

Check the genset for fuel,

oil

or coolant leaks.

If

any are found, shut down the genset and repair the leak before making any more checks.

Connect an accurate AC voltmeter and frequency meter across

two

line terminals. Apply load to the

generator and check output voltage and frequency.

Output frequency

is

determined by engine speed and

normally does not require adjustment Verify that frequency is correct before making any voltage adjustments. Call an authorized Onan distributor or dealer for assistance if needed.

If the voltage is not within specs, it can be adjusted for the generator connection used as shown in the Figure

8-3

table. Before making any adjustments, disable the

genset

by

removing the negative

(-)

cable at the battery.

Accidenial starting

of

the generafor

-1

set can cause severe personal injury

or

death. Disconnect the negative

(-)

baffery cable

before adjusting fhe regulator transformer taps.

9-1

.

Section

10.

DC

Wiring Diagram

This section contains

DC

wiring diagram number

612-6539

forthe

MCE

generator set.

Use

this diagram in conjunction with the wiring information in Section

8

of

this manual

to

make the electrical con-

nections necessary

to

operate the set.

*

10-1

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ENOIN

10-2

Onan Corporation 1400

73rd

Avenue N.E.

Minneapolis, MN 55432 612-574-5000 International Use

Telex:

275477

Fax:

612-574-8087

Onan

is

a

registered

trademark

of

Onan

Corporation

1

-800-888-ONAN