Installation Manual

Generator Set

MDKBH (Spec A−D)

English − Original Instructions 2−2010 981−0647 (Issue 3)

 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Emissions Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
2. OPERATOR CONTROL PANELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Local Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Engine Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Fire Extinguisher Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Priming the Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Starting the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Stopping the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Loading the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
No-Load Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Connecting to Shore Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Resetting Line Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cold Temperature Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Care of New or Re-Built Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Storing the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

i
SECTION PAGE

4. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Periodic Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Changing Engine Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Draining/Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Maintaining the Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
5. ENCLOSURE, DRIP PAN AND MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Enclosure Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Drip Pan and Mounting System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
6. ENGINE AND ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Major Engine Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Intake Resonator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Exhaust Manifold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Glow Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Governor Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
7. GENERATOR DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Inspecting Drive and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
8. GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Servicing the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Servicing Brushes and Slip Rings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Testing Field Flash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Testing Generator Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5

ii
SECTION PAGE

9. GENERATOR SET CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Generator Set Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
Optional Remote Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Local/Remote Control Switch (S4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Emergency Stop Switch (CB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Hour Meter (M11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Engine Oil Pressure Sender (E1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Engine Coolant Temperature Sender (E2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
Battery Charging Regulator (A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
High Exhaust Temperature Switch (S5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Raw Water Flow Switch (S6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Glow Plug Relay (K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Starter Relay (K4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Governor Actuator (A12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Ground Isolation Relay (K9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
Network Interface Module (NIM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8
10. RECONFIGURING VOLTAGE AND FREQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
“As Manufactured” Block on Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Reconnection Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Changing Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Reconnecting Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Adjusting Voltage Using Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Adjusting Voltage Using Optional Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
11. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Troubleshooting with Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Troubleshooting with Status Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
12. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
GENERATOR CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
CONTROL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3

iii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR MANUAL be-  Do not work on the generator set when mental-
fore operating the generator set. Safe operation ly or physically fatigued or after having con-
and top performance can only be obtained sumed alcohol or drugs.
when equipment is operated and maintained
 You must be trained and experienced to make
properly.
adjustments while the generator set is run-
ning—hot, moving or electrically live parts can
The following symbols in this manual alert you to
cause severe personal injury or death.
potential hazards to the operator, service person
and equipment.  Used engine oil has been identified by some
U. S. state and federal agencies as causing
DANGER alerts you to an immediate hazard cancer or reproductive toxicity. Do not ingest,
that will result in severe personal injury or inhale, or contact used oil or its vapors.
death.
 Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
WARNING alerts you to a hazard or unsafe
and dispose of used engine coolant in accor-
practice that can result in severe personal inju-
dance with local environmental regulations.
ry or death.
 Keep multi-class ABC fire extinguishers
CAUTION alerts you to a hazard or unsafe handy. Class A fires involve ordinary combus-
practice that can result in personal injury or tible materials such as wood and cloth; Class B
equipment damage. fires, combustible and flammable liquid fuels
and gaseous fuels; Class C fires, live electrical
Electricity, fuel, exhaust, moving parts and batter- equipment. (ref. NFPA No. 10)
ies present hazards which can result in severe per-
 Generator set installation and operation must
sonal injury or death.
comply with all applicable local, state and fed-
eral codes and regulations.
GENERAL PRECAUTIONS
 Keep children away from the generator set. GENERATOR VOLTAGE IS DEADLY
 Do not use evaporative starting fluids. They  Generator electrical output connections must
are highly explosive. be made by a trained and experienced electri-
cian in accordance with applicable codes.
 Do not step on the generator set when entering
or leaving the generator room. Parts can bend  The generator set must not be connected to
or break leading to electrical shorts or to fuel, shore power or to any other source of electrical
coolant or exhaust leaks. power. Back-feed to shore power can cause
electric shock resulting in severe personal inju-
 To prevent accidental or remote starting while
ry or death and damage to equipment. An ap-
working on the generator set, disconnect the
proved switching device must be used to pre-
negative (−) battery cable at the battery.
vent interconnections.
 Let the engine cool down before removing the
 Use caution when working on live electrical
coolant pressure cap or opening the coolant
equipment. Remove jewelry, make sure cloth-
drain. Hot coolant under pressure can spray
ing and shoes are dry, stand on a dry wooden
and cause severe burns.
platform or rubber insulating mat and use tools
 Keep the generator set, drip pan and compart- with insulated handles.
ment clean. Oily rags can catch fire. Gear
stowed in the compartment can restrict cool- ENGINE EXHAUST IS DEADLY
ing.
 Never sleep in the boat while the generator set
 Make sure all fasteners are secure and proper- is running unless the boat is equipped with
ly torqued. properly working carbon monoxide detectors.

iv
  The exhaust system must be installed in accor- al by those who are trained and experienced in
dance with the generator set Installation marine generator set service.
Manual and be free of leaks.
BATTERY GAS IS EXPLOSIVE
 Make sure the bilge is adequately ventilated
with a power exhauster.  Wear safety glasses.
 Inspect for exhaust leaks every startup and af-  Do not smoke.
ter every eight hours of operation.  To reduce arcing when disconnecting or recon-
 For more information about carbon monoxide necting battery cables, always disconnect the
see American Boat and Yacht Council (ABYC) negative (−) battery cable first and reconnect
publication TH-22—Educational Information it last.
About Carbon Monoxide.
MOVING PARTS CAN CAUSE SEVERE
DIESEL FUEL IS COMBUSTIBLE PERSONAL INJURY OR DEATH
 Do not wear loose clothing or jewelry near
 Do not smoke or turn electrical switches ON or
moving parts such as PTO shafts, fans, belts
OFF where fuel fumes are present or in areas
and pulleys.
sharing ventilation with fuel tanks or equip-
ment. Keep flames, sparks, pilot lights, arc-  Keep hands away from moving parts.
producing equipment and all other sources of  Keep guards in place over fans, belts, pulleys,
ignition well away. and other moving parts.
 Fuel lines must be secured, free of leaks and
separated or shielded from electrical wiring. FLAMMABLE VAPOR CAN CAUSE A
DIESEL ENGINE TO OVERSPEED
GASOLINE IS FLAMMABLE AND
Flammable vapor can cause a diesel engine to
EXPLOSIVE
overspeed and become difficult to stop, resulting in
 Because this generator set is an Ignition Pro- possible fire, explosion, severe personal injury and
tected device, no substitutes are permitted for death. Do not operate a diesel-powered genera-
the parts listed in the Critical Parts Index of the tor set where a flammable vapor environment
generator set Parts Catalog. They must be can be created by fuel spill, leak, etc. The owners
purchased from Onan and be installed in ac- and operators of the generator set are solely re-
cordance with the generator set Service Manu- sponsible for operating the generator set safely.

POST THESE SAFETY PRECAUTIONS IN POTENTIAL

HAZARD AREAS OF THE BOAT
M-11

v
1. Introduction
ABOUT THIS MANUAL You must find out which standards for safety are ap-
plicable. Compliance with United States Coast
This manual is a guide for the installation of the gen- Guard (USCG) regulations is mandatory for boats in
erator sets listed on the front cover. Proper installa- U. S. waters. The American Boat and Yacht Council
tion is essential for top performance. Read through (ABYC) and the National Fire Protection Associa-
this manual before starting the installation. tion (NFPA) are typical of agencies that publish
safety standards for the construction and installa-
This manual addresses the following aspects of the tion of marine equipment. It is suggested that you
installation: obtain the following standards:
 Location and mounting  USCG regulations are under Titles 33 and 46 of
 Engine exhaust discharge and silencing the Code of Federal Regulations (CFR),
 Engine cooling U.S. Government Printing Office
Washington, D.C. 20404.
 Generator set room ventilation
 NFPA No. 302, Pleasure and Commercial Mo-
 Fuel connections tor Craft,
 Electrical connections National Fire Protection Association
 Batteries Batterymarch Park
Quincy, MA 02269
 Bonding for grounding
 Standards and Recommended Practices For
 Accessibility for operation and maintenance Small Craft,
 Noise and vibration. American Boat and Yacht Council, Inc.
3069 Solomons Island Road
WARNING This generator set is not a life sup-
Edgewater, MD 21037
port system. It can stop without warning. Chil-
dren, persons with physical or mental limita- Particular attention should be paid to ABYC P-1,
tions, and pets could suffer personal injury or Installation of Exhaust Systems for Propulsion and
death. A personal attendant, redundant power Auxiliary Machinery, ABYC E-11, AC and DC Elec-
or an alarm system must be used if generator trical Systems on Boats and ABYC A-27, Alternat-
set operation is critical. ing Current (AC) Generator Sets.
See the generator set Operator’s Manual for opera- OUTLINE DRAWINGS
tion and maintenance and the Service Manual for
service. See the OUTLINE DRAWING (p. A-4) for installa-
tion details: mounting bolt hole locations, connec-
Note: Manuals are updated from time to time to re-
flect changes in the equipment and its specifica-
tion points (fuel, battery, raw water, exhaust, remote
tions. For this reason, only the copy of the installa- control and AC output), sizes and types of fittings,
tion manual supplied with the generator set should overall dimensions, etc. See your Onan dealer for
be used as a guide for the installation. large-scale copies of the drawing.

STANDARDS FOR SAFETY WARNING Improper installation can result in

severe personal injury, death and equipment
This generator set is suitable for installation in ac- damage. The installer must be qualified to per-
cordance with USCG Pleasure Craft Regulations form installation of electrical and mechanical
and ISO Small Craft Standards. equipment.

1-1
2. Location and Mounting
LIFTING THE GENERATOR SET  Checking, filling and draining engine oil
 Changing the engine oil filter
The generator set weighs 365 pounds (166 kg).
Use both lifting eyes, which are accessible by re-  Checking, filling and draining engine coolant
moving the top access door (Page A-4), and proper  Replacing coolant and exhaust hoses
equipment for safe handling.
 Replacing the raw water pump impeller
Save the four steel clamps that secured the genera-  Replacing the V-belt
tor set to the shipping skid if they are to be used for
securing the generator set to the floor or frame of the  Changing the fuel filter
boat. See MOUNTING THE GENERATOR SET.  Making fuel connections
LOCATION  Making battery and ground connections
 Making AC connections
See the other sections titled Ventilation, Fuel Sup-
ply, Engine Cooling and Engine Exhaust for addi-  Making remote control connections
tional considerations that bear on location.  Inspecting the drive belt system and generator
bearing at the back of the generator set
This generator set is ignition protected and there-
fore permitted under USCG regulation 33CFR183 MOUNTING
to be located in a gasoline fuel environment.
The generator set has integral vibration isolators.
Because of noise, vibration and fumes, the genera- The supporting structure underneath should be lev-
tor compartment should be located as far from living el and able to support the weight of the generator
quarters as practical. set. Floor or frame stiffness should be greatest un-
Locate the generator set where there will be enough der the vibration isolators. Secure the generator set
room to perform periodic maintenance and service. to the floor or frame in one of the following ways:
The back should have at least 2 inches (51 mm) of  By bolting it with three (3) bolts through the bolt
clearance. The left side and front should have at holes in the drip pan (p. A-4).
least 1 inch (25 mm) of clearance for air flow. The  By clamping it with the four (4) steel clamps that
top must have at least 2 inches (51 mm) of clear- secured it to the shipping skid: one at each cor-
ance to unlatch the access door. The right side must ner (p. A-4). A clamp can be on either side of a
have enough clearance to remove the side panel for corner.
adjusting the V-belt, replacing the pump impeller
and servicing the heat exchanger. See the OUT-  By bolting it through the front bolt hole in the
LINE DRAWING (p. A-4). drip pan and clamping each rear corner with a
steel clamp.
Make sure there is access for:
To reduce noise, plug the unused clamp openings in
 Starting and stopping the generator set
the drip pan with the four rubber plugs shipped in the
 Resetting the line circuit breakers literature packet.

2-1
3. Ventilation
WARNING EXHAUST GAS IS DEADLY—FUEL life of electrical components, generator windings,
VAPORS ARE EXPLOSIVE! Failure to provide rubber and other construction materials.
proper ventilation can result in asphyxiation,
fire and explosion. The ventilation system must CARBON MONOXIDE
meet applicable standards and regulations, in-
cluding USCG, NFPA and ABYC (p. 1-1). All openings and feed-through holes for wiring, con-
duit, pipe and hose must be sealed to prevent ex-
VENTILATION haust gases from entering the rest of the boat. Wir-
ing conduit must be sealed inside as well as outside.
Ventilation is required to prevent dangerous con-
centrations of fuel vapors and exhaust fumes, hold Cabin plumbing drains must have approved traps to
down compartment temperatures and provide com- prevent the entrance of exhaust gases from outside.
bustion air. The highest compartment temperatures Carbon monoxide (CO) detectors, listed for marine
can occur just after the boat has been docked and applications, should be installed in the living quar-
the engines have been shut down. ters of the boat. Wind shifts, boat motion, exhaust
To promote natural convective flow, good air ex- from other docked boats and other conditions can
change and fresh air for combustion and generator cause exposure to harmful concentrations of car-
cooling, ventilating air should enter near the bottom bon monoxide even when proper ventilation is pro-
of the compartment at the front near the air inlet and vided and living quarters are sealed off from engine
exit near the top at the right side. The free-air area of rooms.
the inlet air cowl should be at least twice that of the
duct. Use 40 in2 (258 cm2) as the basis for calcula- IGNITION PROTECTION
tions for inlet and outlet air duct sizes and free-air
areas of screens and louvers. Do not use flush air The generator set is ignition protected and therefore
inlets or louvered transom outlets, which are easily permitted under USCG regulation 33CFR183 to be
blocked. located in a gasoline fuel environment.

Operating a generator set in ambient temperatures All electrical devices, such as switches, circuit
above 104 F (40 C) will result in noticeable loss of breakers, meters and control panels used in areas
power. Operating a generator set in ambient tem- where gasoline vapors can accumulate must be
peratures higher than 122 F (50 C) will reduce the Ignition Protected.

3-1
4. Fuel Connections

WARNING Improper storage and handling of Fuel Line Sizing

Diesel Fuel can lead to fire. Fuel tank construc-
tion, location, installation, bonding for ground- An inside diameter of 5/16 inch (8 mm) is recom-
ing, ventilation, piping, inspection and leak test- mended for fuel lines and hoses. An inside diameter
ing must be in accordance with applicable stan- of 1/4 inch (7 mm) should be considered in applica-
dards and regulations, including USCG, NFPA tions where fuel lines are short and lift minimal. See
and ABYC (p. 1-1). Fuel Lift in this section. Larger diameter fuel lines
are harder to prime and keep primed and are thus
CAUTION Do not use galvanized fuel tanks or more likely to cause disruption of generator set ser-
piping. The trace of sulfur in diesel fuel attacks vice.
galvanized (zinc) coatings causing debris that
can clog fuel filters, pumps and injectors. Run fuel lines as directly as possible avoiding dips
and crests that trap air and cause hard priming.
Fuel
Fuel Pickup Tube
See the Operator’s Manual for recommended fuel.
A separate fuel pickup tube and supply line is re-
Fuel Filters quired for each generator set. Shared pickup tubes
and distribution manifolds can lead to fuel starvation
The generator set is equipped with a and difficult priming.
water-separator fuel filter. It is recommended that a
10 to 30 micron water-separator fuel filter be See Fuel Line Sizing in this section for recom-
installed in the fuel supply system to protect the fuel mended sizing.
lift pump. In a common fuel supply tank the generator set pick-
up tubes should be shorter than the propulsion en-
Fuel Fittings
gine pickup tubes to prevent the generator sets from
Two 1/4-18 NPTF fittings are provided for fuel sup- being able to empty the fuel tanks.
ply and return connections. See the OUTLINE
Make sure the fuel tanks are large enough to cool
DRAWING (p. A-4). Fuel hose adapter fittings are
the returning fuel and that the supply and return
available from Onan.
pickup tubes are separated by at least 10 inches
Fuel Hoses (254 mm) to reduce the recirculation of hot fuel.

Use USCG TYPE A1 or ISO 7840-A1 fuel hoses. Fuel Shutoff Valves
See Fuel Line Sizing in this section for recom-
mended sizing. A fuel shutoff valve is required at the fuel tank if the
end of the fuel line is located below the highest level
The fuel hoses connected at the generator set must of fuel in the tank.
be non-conductive so that the fuel lines do not be-
come paths for cranking current. (Because the fuel An approved method is required to prevent flow
tanks are required to be bonded to the common when the engine is not running if the highest level of
negative [−] grounding system of the boat, conduc- fuel in the supply tank is above the fuel injectors.
tive fuel lines connected directly to the generator set
will carry cranking currents.) Fuel Lift
WARNING Fire can result when fuel lines carry The fuel lift pump on the generator set has a fuel lift
cranking current. Use non-conductive fuel capability (suction) of 4 feet (1.2 meters). Note that
hoses for connections at the generator set to the pump must overcome the resistance to fuel flow
prevent the fuel lines from becoming paths for in hoses, tubing, fittings, valves and filters as well as
cranking current. the actual lift in elevation.

4-1
5. Engine Cooling
The engine is cooled by a pressurized, closed-loop water strainer for faster priming at startup if it is
liquid cooling system in which coolant is pumped above the water line.
through passages in the engine block, head and ex-
haust manifold (Figure 5-1). Heat is carried away Sea Cock
from the coolant by a heat exchanger mounted in-
side the exhaust manifold, which also serves as the Install a bronze, full-flow sea cock on the through-
engine coolant reservoir. Raw water (the flotation hull fitting.
water) is pumped through tubes in the heat ex-
changer to cool the engine coolant and is then Through-Hull Fitting and Strainer
passed through a hose into the exhaust-water mixer
to cool the exhaust gases. The raw water is expelled The through-hull fitting should be as close to the
from the boat along with the exhaust gases. The V- generator set as possible. If the strainer has slotted
belt drives the coolant and the raw water pumps. openings, the slots must be parallel to the keel for
See the OUTLINE DRAWING (p. A-4) for connec- best flow when the boat is under way. Through-hull
tion points and fitting sizes. fittings should be staggered along the keel so that
downstream fittings are not starved.
SYSTEM COMPONENTS
CAUTION Do not use a scoop-type through-
Raw Water Pump hull fitting. A forward-facing scoop can develop
enough ram pressure to flood the engine. A
The raw water pump can deliver the required flow of rear-facing scoop can develop enough suction
cooling water against a maximum lift (suction) of to impede flow.
4 feet (1.22 meters). Lift is a combination of the ac-
tual vertical lift and the resistance to flow caused by Siphon Break
the hoses, strainer, sea cock and through-hull fit-
ting. Conduct the RAW WATER PICKUP TEST to deter-
mine whether a siphon break is required to prevent
The pump impeller must be wetted with water to es- the muffler and engine from being flooded with
tablish initial pump lubrication and suction. See gen-
floatation water. Siphon Break Kit 541-0876 is avail-
erator set the Operator’s Manual. able if a siphon break is required. Carefully follow
Raw Water Hose the instructions in the kit. The hoses in the kit re-
place the hose between the engine heat exchanger
Use SAE 20R4 or equivalent hose that is able to re- and exhaust-water mixer (Figure 6-2). The end
sist a slight vacuum without collapsing. The fitting panel of the generator set has knockouts for the
on the raw water pump inlet is sized for 5/8 inch hoses to pass through. See the OUTLINE DRAW-
(15.9 mm) internal diameter hose. This size should ING (p. A-4). The kit has the hole grommets.
be used for all hoses and pipes in the raw water pick-
up line. To keep leaks from spilling on the generator set, do
not mount the siphon break directly above the gen-
Raw Water Strainer erator set.

The raw water strainer should be located below and CAUTION Engine damage due to flooding as a
as close to the raw water pump as practical. The result of failing to install a required siphon break
basket must be removeable for cleaning. Fill the sea is not covered by Warranty.

5-1
Coolant Recovery Tank Method

The coolant recovery tank kit shipped with the gen- When the boat is ready for its sea trials and loaded
erator set must be installed for proper operation of to its maximum rated capacity:
the cooling system. Follow the instructions in the kit. 1. Close the sea cock and disconnect the raw wa-
ter pickup hose from the generator set. Alterna-
The tank must be accessible for daily inspection and tively, connect a clear plastic hose to the strain-
refilling. Clamp the recovery hose to the hose barb er or sea cock.
on the coolant fill neck (Figure 5-1). Route the tank 2. Raise the end of the hose above expected wa-
recovery and overflow hoses through the holes in ter level and open the sea cock. The water line
the end of the enclosure. See the OUTLINE DRAW- is at the level visible in a clear plastic hose or
ING (p. A-4). Make sure the overflow hose termi- where water just begins to spill as the end of the
nates in the drip pan where it will not splash coolant hose is lowered. While the boat is still docked,
on electrical components. Fill the tank in accor- mark the level on the generator set enclosure.
dance with the Operator’s Manual.
3. Operate the boat through its speed range, for-
Initial Coolant Fill ward and reverse. While the boat is operating,
have someone monitor the water level in the
hose and mark the highest level on the genera-
The generator set is normally shipped from the fac-
tor set.
tory with coolant, unless prohibited by shipping reg-
ulations. Fill the system, if necessary, in accordance Requirement
with the Operator’s Manual.
A siphon break must be installed if the siphon point
CAUTION Running the engine without coolant (Figures 6-3 and 6-4) is not at least 6 inches
can cause damage not covered by Warranty. (152 mm) above both water lines (docked and mov-
ing).
RAW WATER PICKUP TEST Note: If the water line when the boat is moving is
much higher than when the boat is docked, the differ-
ence could be due to the through-hull fitting or its
Objective
location. If the through-hull fitting is of the forward-
facing scoop-type designed to create ram pressure,
The objective is to determine the elevation of the replace it with a flush-type fitting. Another possibility
water line relative to the generator set under all an- might be to move the fitting to a location where the
ticipated uses and speeds of the boat. dynamic hull pressure is less.

5-2
HEAT EXCHANGER RAW WATER PRESSURE CAP & HOSE BARB TO CONNECT EXHAUST
CLEANOUT COVER FLOW SENSOR COOLANT FILL NECK COOLANT RECOVERY TANK MANIFOLD &
COOLANT
RESERVOIR

THERMOSTAT
HOUSING COULD BE
CONNECTED TO
EXTERNAL SIPHON
BREAK AT THIS
POINT—SEE
COOLANT INSTALLATION
PUMP MANUAL

BLOCK EXHAUST-WATER
DRAIN CAP MIXER WITH HIGH
TEMPERATURE
EXHAUST SWITCH

EXHAUST & RAW

WATER OUT
RAW WATER
PUMP

COOLANT
RAW WATER RAW WATER IN

FIGURE 5-1. ENGINE COOLING SYSTEM

5-3
6. Engine Exhaust
WET EXHAUST SYSTEMS (42 mm/meter) and be supported such that there
are no sags. The entire run of hose must be
WARNING EXHAUST GAS IS DEADLY! The ex- accessible for regular, visual inspections and
haust system must be leak-free and convey all replacement.
exhaust outside, away from windows, doors
and vents. Hose Clamps

Figures 6-1 and 6-2 illustrate typical exhaust sys- Use two stainless steel hose clamps at least
tems where the raw water fitting on the siphon point 1/2 inch (12.7 mm) wide to clamp each end of each
is above the load water line and Figures 6-3 and 6-4 hose.
where it is below. See Engine Cooling (Section 5)
regarding raw water connections. The installation
Muffler
must comply with applicable standards and regula- Install an approved muffler as close as practical to
tions, including those of the USCG and ABYC the engine. The length of hose between the genera-
(p. 1-1) tor set and muffler should be 1 to 5.5 feet (30
to 170 cm). The muffler inlet should be a minimum
A separate engine exhaust system must be
of 1 foot (305 mm) below the siphon point and the
installed for each generator set. It must be isolated
outlet should be vertical.
from all other engine exhaust systems.
The base of the muffler should not be more than
Mufflers, water separators and siphon breaks are 54 inches (1.4 meter) below the water separator
available as kits from Onan. (Figure 6-1) or 48 inches (1.2 meter) below the
crest in the piping (Figure 6-2).
Hose and Hose Fitting Diameters
Mount the muffler such that air can circulate under-
No hose or hose fitting in the exhaust system may neath to prevent condensation and mold.
have a smaller inside diameter than the engine out-
let. If the total run of exhaust hose is more than Exhaust Water Separator
20 feet (6 meters), measure exhaust back pressure
and use larger diameter hose if back pressure ex- When an exhaust water separator is used (Fig-
ceeds specifications. See Specifications (Sec- ure 6-1), the muffler outlet and water separator inlet
tion 10). diameters must be the same size. The water sepa-
rator should be installed directly above the muffler to
Exhaust Hose maintain a vertical lift. The through-hull fitting for the
drain hose should be below the load water line and
Use hose that has been approved for wet exhaust must have a sea cock. An EXHAUST WATER SEP-
systems. Approved hose and stainless steel elbows ARATOR BACKFLOW TEST must be conducted
are available from Onan. Horizontal runs of hose during the sea trials to determine that there is no
must slope down at least 1/2 inch per foot backflow that could flood the engine.

6-1
Exhaust Through-Hull Fitting EXHAUST WATER SEPARATOR
BACKFLOW TEST
The exhaust through-hull fitting must be above the
load water line under all anticipated uses and Objective
speeds of the boat. To reduce wave wash-in when a
To determine that there is no backflow through the
water separator is used (Figure 6-1), the top of the
exhaust water separator under any operating condi-
water separator must be at least 18 inches
(450 mm) above the load water line. When an elbow tion (Figure 6-1).
is used at the top of the muffler outlet hose, the el- Method
bow must be at least 12 inches (305 mm) above the
through-hull fitting (Figure 6-2). Conduct this test during the sea trials in conjunction
with the RAW WATER PICKUP TEST. Prepare by
CAUTION Backflow can cause major engine closing the drain hose sea cock and disconnecting
damage if the cylinders become flooded. The the hose from the water separator. Conduct the test
sea trials must verify that there is no backflow by opening the sea cock while keeping the hose
through either the exhaust hull fitting or the wa- raised to its fitting on the water separator.
ter separator drain hose fitting.
Requirement
Siphon Break There must not be any back flow while operating the
boat throughout its speed range. If there is, relocate
See Page 5-1. the through-hull fitting.

6-2
 SIPHON BREAK NOT REQUIRED WHEN SIPHON POINT
IS AT LEAST 6 INCHES (152 MM) ABOVE LOAD WATER LINE

WATER
SEPARATOR
54 INCH
(1.4 METER)
MAX.

18 INCH
(457 MM)
MIN.

12 INCH
GENERATOR SET (305 MM)
MIN.
6-3

LOAD
WATERLINE

SEA
SIPHON POINT COCK
SEE OUTLINE DRAWING MUFFLER
(P. A-4) 6 INCH MUST BE
(152 MM) ABOVE
MAX. WATERLINE
Notes:
1. All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).
2. The operator will not be able to look for water discharge from the hull to tell whether engine/exhaust cooling water is flowing. However, the
generator set will shutdown if water stops flowing (Code No. 7). See Troubleshooting in the Operator Manual.

FIGURE 6-1. TYPICAL INSTALLATION ABOVE LOAD WATERLINE—WITH MUFFLER AND WATER SEPARATOR
 SIPHON BREAK NOT REQUIRED WHEN SIPHON POINT
IS AT LEAST 6 INCHES (152 MM) ABOVE LOAD WATER LINE

12 INCH
(305 MM)
MIN.

GENERATOR SET
12 INCH
(305 MM)
MIN.
6-4

LOAD WATERLINE

48 INCH
(1.2 METER)
MAX.

SIPHON POINT MUFFLER

SEE OUTLINE DRAWING MUST BE ABOVE
(P. A-4) WATERLINE

Note: All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).

FIGURE 6-2. TYPICAL INSTALLATION ABOVE LOAD WATERLINE—WITH MUFFLER AND RESONATOR
 SIPHON BREAK REQUIRED WHEN SIPHON POINT IS
BELOW OR LESS THAN 6 INCHES (152 MM) ABOVE LOAD WATER LINE

SIPHON
BREAK
VALVE

WATER
SEPARATOR
54 INCH
(1.4 METER)
MAX.
12 INCH
(305 MM) 18 INCH
MIN. (457 MM)
MIN.

GENERATOR SET

LOAD
6-5

WATERLINE

12 INCH SEA
(305 MM) COCK
MIN.

SIPHON POINT MUFFLER

SEE OUTLINE DRAWING 6 INCH MUST BE
(P. A-4) (152 MM) ABOVE
MAX. WATERLINE
Notes:
1. All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).
2. The operator will not be able to look for water discharge from the hull to tell whether engine/exhaust cooling water is flowing. However, the
generator set will shutdown if water stops flowing (Code No. 7). See Troubleshooting in the Operator Manual.

FIGURE 6-3. TYPICAL INSTALLATION BELOW LOAD WATERLINE—WITH SIPHON BREAK, MUFFLER AND WATER SEPARATOR
 SIPHON BREAK REQUIRED WHEN SIPHON POINT IS
BELOW OR LESS THAN 6 INCHES (152 MM) ABOVE LOAD WATER LINE

SIPHON
BREAK
VALVE

12 INCH
(305 MM)
MIN. 12 INCH
(305 MM)
MIN.

GENERATOR SET
6-6

LOAD WATERLINE

12 INCH
(305 MM) 48 INCH
MIN. (1.2 METER)
MAX.

SIPHON POINT MUFFLER MUST BE ABOVE

SEE OUTLINE DRAWING
(P. A-4) WATERLINE

Note: All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).

FIGURE 6-4. TYPICAL INSTALLATION BELOW LOAD WATERLINE—WITH SIPHON BREAK, MUFFLER AND RESONATOR
7. Electrical Connections
WARNING HAZARDOUS VOLTAGE! Touching Grounding
uninsulated live parts inside the generator set
and connected equipment can result in severe The generator set, power supply wiring and all con-
personal injury or death. For your protection, nected electrical equipment must be bonded to the
stand on a dry wooden platform or rubber insu- common grounding system of the boat in accor-
lating mat, make sure your clothing and shoes dance with applicable regulations.
are dry, remove jewelry from your hands and
use tools with insulated handles. Secure pro- WARNING Faulty grounding of electrical
tective covers when completing installation. equipment can lead to fire or electric shock re-
sulting in severe personal injury or death.
IMPROPER WIRING can cause fire or electric Grounding must be accomplished in accor-
shock resulting in severe personal injury or dance with applicable regulation.
death.
Transfer Switch
ACCIDENTAL / REMOTE STARTING of the gen- Use an approved transfer switch if provision is made
erator set can cause severe personal injury or for connecting the boat to shore power.
death. To prevent unintended starting, do not
connect the starting battery until it is time to WARNING Backfeed to shore power can cause
start up the generator set. electric shock resulting in severe personal inju-
ry or death and damage to equipment. Use an
AC OUTPUT CONNECTIONS approved device to prevent the generator set
from being interconnected with shore power.
Wiring Methods
Load Balancing
All wiring methods, connections, wire ampacities,
equipment grounding and materials must be in- The electrical loads on the generator should be bal-
spected and comply with applicable regulations. anced as closely as possible between the AC output
Use flexible conduit and stranded conductors for legs so that maximum power can be utilized from
load wiring to take up movement and vibration. the generator set. Redistribute the loads as neces-
sary.
Note: All feed-through holes in decks and bulkheads
for wiring must be sealed to prevent exhaust gases BATTERY CONNECTIONS
and flammable vapors from entering the rest of the
boat. Wiring conduit must be sealed inside as well as The generator set requires negative (−) ground,
outside 12 VDC for its control and cranking systems. Some
models are equipped for applications requiring an
Generator (Alternator) Connections isolated ground.

Batteries
Make generator connections in the AC output box.
See Page A-2 for the appropriate generator con- See Specifications (Section 10) for recommended
nection schematic and the OUTLINE DRAWING battery capacity.
(p. A-4) for the location of the AC access knockouts.
Battery Recharging
See Reconfiguring Voltage and Frequency (Sec-
tion 8) if application voltage is different from “As See Specifications (Section 10) for the battery
Manufactured” voltage. charging rate.

7-1
Disabling Battery Charger Size battery cables according to Table 7-1. Total
cable length is the sum of the lengths of the positive
If it is necessary to disable battery charging for the (+) and negative (−) cables. In other words, total
application, disconnect the leads marked B1, B2 cable length will be approximately twice the dis-
and B+ from the quick-connect terminals on battery tance between the battery and the generator set.
charging voltage regulator (p. A-1). The regulator is
mounted on the left wall inside the access opening TABLE 7-1. BATTERY CABLE SIZES
on the left end of the generator set. Insulate the end Total Cable Length, Cable Size,
of each lead with several wraps of listed electrical in- Feet (Meters) AWG
sulating tape and tie them neatly into the wiring har- 10 (3) 4
ness. Secure the access cover when done.
14 (4.3) 3
Battery Location and Mounting 18 (5.5) 2
22 (6.7) 1
WARNING Arcing can ignite the explosive hy-
30 (9.1) 1/0
drogen gas given off by the battery, causing se-
vere personal injury. The battery compartment See the OUTLINE DRAWING (p. A-4) regarding the
must be ventilated and isolated from spark-pro- battery cable terminal locations. Provide an insulat-
ducing equipment. ing boot over the positive (+) terminal to protect
against accidental contact.
Locate the battery where spills and leaks will not
drip acid on fuel lines, wiring or other equipment and GENERATOR SET GROUND
where ventilation is adequate to prevent the accu- (VESSEL BOND)
mulation of explosive gases. Secure the battery so
that it cannot shift and provide a boot over the posi- The generator set must be bonded to the common
tive (+) terminal to protect against accidental con- grounding system of the boat in accordance with ap-
tact. plicable regulations. Connect the bonding cable to
the grounding lug beside the battery cable termi-
Battery Cables nals.

WARNING Sparks can ignite fuel leading to se- WARNING Faulty bonding of the generator set
vere personal injury or death. Do not run battery to the common grounding system of the boat
cables and fuel lines together. Separate cables can result in severe personal injury or death.
and fuel lines with conduit or tubing if run Grounding must be accomplished in accor-
through the same opening. Do not tie together. dance with applicable regulation.

7-2
 REMOTE CONTROL CONNECTOR applications requiring more than one remote control
station.
Connector J4 for remote control connections
(p. A-1) is stowed inside the control box. It mates Non-Onan Harnesses: Use 16 AWG wiring.
with a Deutsch Part Number DT06−08S sealed
8-pin connector plug. Note: All feed-through holes in decks and bulkheads
for wiring must be sealed to prevent exhaust gases
Note: The connector designated J44 is for remote and flammable vapors from entering the rest of the
connections when the optional Network Interface boat. Wiring conduit must be sealed inside as well as
Module (NIM) is provided. outside.

Onan e-Series Digital Displays Note: Do not route remote control wiring near AC wir-
ing. AC can induce false signals that can cause errat-
Up to three (3) Onan e-Series Digital Displays may ic operation of the generator set.
be connected for remote control and monitoring of
the generator set. Follow the installation instruc- EXTERNAL CUSTOMER CONNECTIONS
tions in the kit.
The generator set control box has factory jumpered
Remote Control Switch and Meter leads with quick-connect terminals labeled SWB+,
ESTOP and CO for connecting external generator
Onan Remote Control Panel Kit: Remote control set shutdown devices (p. A-1). Connect ESTOP to
panels with a control switch or control switch and an emergency shut down system, such as for fire
hour meter are available as kits. Follow the installa- suppression, and CO to a CO detector. Leave the
tion instructions in the kit. factory jumper connected if an external connection
is not made, otherwise the generator set cannot run.
Non-Onan Remote Control Panels: Refer to the
wiring diagrams on Page A-1 to select and connect The e-Series Digital Display will display Code
the remote control panel components. The Start- No. 5—SHUTDOWN DUE TO VESSEL CO or
Stop switch must be momentary contact in both Code No. 61—EXTERNAL SHUTDOWN if shut-
positions. down occurs. See Troubleshooting (Operator’s
Manual).
Remote Control Wiring Harnesses
Models with Option H647 (p. A-1) have a relay and
Onan Harnesses: Eight-conductor plug-in wiring connector (J14/P14) for connection to the external
harnesses of various length are available for con- customer circuits. Leave connector P14 connected
necting e-Series Digital Displays and/or remote if an external connection is not made, otherwise the
switch panels. “Y” harnesses are also available for generator set cannot run.

7-3
 OPTIONAL NETWORK INTERFACE
MODULE (NIM)
The optional NIM board is mounted in a box on the
side of the generator set. See Page A-1 for connec-
tions. It has an open 12-Pin connector socket for ex-
ternal network connections that mates with a
Deutsch Part Number DT06−12S sealed 12-pin
connector plug.
Note: For SAE 1939 applications see your Onan dis-
tributor for more information. Onan Publication
D-3315, Supported Messages on SAE J1939, must be
used in designing the interface for monitoring gener-
ator set status and diagnostics.
Note: For SmartCraft applications see your Cum-
mins MerCruiser Distributor for more information.
FIGURE 7-1. NETWORK INTERFACE MODULE
The NIM board has five jumpers to configure the CONFIGURATION JUMPERS
board for the specific application (Figure 7-1).
1. Jumper W1 has no function at this time.
2. Jumper W2 will be cut when the generator set
is ordered for an SAE J1939 network applica-
tion. The jumper must remain uncut when the
generator set is ordered for a SmartCraft net-
work application.
3. For J1939 applications jumpers W3 and W4 are
used to assign the network addresses of the
generator sets in a multiple-generator set
installation. To assign an address, cut the jump-
ers as scheduled in Table 7-2.

For SmartCraft applications see your Cum-

mins MerCruiser Distributor.
TABLE 7-2. J1939 ADDRESSES
Jumper W3 Jumper W4 Address
Not Cut Not Cut 234
Not Cut Cut 158
Cut Not Cut 179
Cut cut 203

4. Cut Jumper W5 if the bus termination resistor

on this NIM board is not required to terminate
the network bus. (The jumper is cut on a Smart-
Craft board.)

SmartCraft is a trademark of the Brunswick Corporation.

7-4
8. Reconfiguring Voltage and Frequency
“AS MANUFACTURED” BLOCK ON
NAMEPLATE

The generator set was set up and adjusted at the

factory for the frequency and voltage stated in the
“As Manufactured” block on the nameplate (Fig-
ure 8-1). If it is necessary to reconfigure voltage
and/or frequency for the application, follow the in-
structions 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
generator set nameplate (Figure 8-1) when reconfi-
guring the generator set for the application. Apply FIGURE 8-1. “AS MANUFACTURED” BLOCK ON
the appropriate label if different from the “As NAMEPLATE
Manufactured” data block.

CHANGING FREQUENCY

The generator set control box has three frequency

selection jumper leads terminated in connectors J5,
P6 and P7 (p. A-1). If application frequency is differ-
ent from “As Manufactured” frequency:
 Connect J5 to P6 for 60 HZ.
 Disconnect J5 from P7 for 50 HZ.
 Apply the appropriate reconfiguration label.

RECONNECTING GENERATOR

WARNING Accidental or remote starting can

cause severe personal injury or death. Before
removing a panel or access door, disconnect
the negative (−) cable at the battery to prevent
the engine from starting.
FIGURE 8-2. RECONNECTION LABELS
Reconnect the generator for the application voltage,
if necessary, in accordance with the appropriate
generator connection schematic on Page A-2. Ap-
ply the appropriate reconfiguration label and 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 generator set
power when reconnecting the generator.

8-1
 ADJUSTING VOLTAGE USING CONTROL 2. Rapidly press START 6 times during the first
SWITCH minute after startup to put the generator set
controller into voltage adjust mode. The green
1. Start the generator set and let voltage and fre- status lamp will blink rapidly and the Display will
quency stabilize for 5 to 10 seconds. Make sure indicate a Status change from Running to Volt
all loads have been disconnected. Adj (Figure 8-3).

2. Rapidly press START 6 times during the first 3. To adjust voltage up, press and quickly re-
minute after startup to put the generator set lease START. Voltage will increase approxi-
controller into voltage adjust mode. The amber mately 0.6 volts each press and release.
status lamp will begin blinking about once every
second to indicate the change to voltage adjust 4. To adjust voltage down, press and hold
mode. The green status lamp will remain on. START for about 1 second. Voltage will de-
crease approximately 0.6 volts each press and
3. To adjust voltage up, press and quickly re-
release.
lease START. Voltage will increase approxi-
mately 0.6 volts each press and release.
5. When satisfied with the adjustment, wait about
4. To adjust voltage down, press and hold 20 seconds for the Operator Panel to indicate
START for about 2 second. Voltage will de- a Status change from Volt Adj to Running and
crease approximately 0.6 volts each press and then press STOP to stop the generator set and
release. save the adjustment.

5. When satisfied with the adjustment, wait about 6. Restart the generator set and check voltage.
20 seconds for the amber lamp to stop blinking
and then press STOP to stop the generator set 7. Recalibrate AC Voltage on the Operator Panel
and save the adjustment. as instructed in the Operator’s Manual.
6. Restart the generator set and check voltage.

ADJUSTING VOLTAGE USING OPTIONAL

OPERATOR PANEL
Volt Adj
Note: The GEN STATUS screen will not display AC
Voltage while the generator set 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 generator set and let voltage and fre-

quency stabilize for 5 to 10 seconds. Make sure
all loads have been disconnected. FIGURE 8-3. VOLTAGE ADJUSTMENT SCREEN

8-2
9. Installation Review and Startup
Before starting the generator set, review the  The generator set is bonded to the boat ground-
installation checklist below for those items that do ing system in accordance with regulations.
not require the generator set to be actually running.  All grounded cranking motor circuits are con-
Make necessary reconnections, modifications and nected by properly sized common bonding
repairs. Then start and operate the generator set in conductors.
accordance with the Operator’s Manual, observing
all of its instructions and precautions. Continue  If required, the kit for isolated DC ground was
working through the installation checklist with the installed.
generator set running, making necessary recon-  An approved transfer switch prevents intercon-
nections, modifications and repairs. Check off () nections between shore power and generator
each item that can be answered positively. Do not set.
place the generator set in service until each item
has been checked off.  AC wiring methods, materials and bonding for
grounding meet regulations.
 The RAW WATER PICKUP TEST was con-  A properly sized battery has been installed, ser-
ducted during the sea trials to establish the wa- viced and charged. The battery is securely
ter line and a siphon break was installed, if mounted in an adequately ventilated space and
found necessary. the positive (+) terminal is shielded from acci-
 The sea trials established that there is no back- dental contact.
flow through the exhaust through-hull fitting or  Remote e-Series Digital Displays and control
water separator drain hose when the boat is un- switches function as intended.
der way, forward or reverse.
 Emergency and/or CO detection and shutdown
 Generator set compartment ventilation meets devices have been connected and have been
regulations and the sea trials established that tested to determine that the generator set shuts
ventilation is sufficient to maintain acceptable down as intended.
generator set compartment temperatures,  The generator set is properly sized for the ap-
even while “heat soaking” after returning and plication, the voltage and frequency are correct
docking. and the loads across a multi-phase generator
 All electrical devices used in spaces where are balanced.
gasoline vapors can accumulate are Ignition  Exhaust back pressure is acceptable.
Protected.
 The exhaust system is leak-free and conveys
 The living quarters are sealed against leaks all engine exhaust outside, away from win-
from spaces where exhaust and fuel vapors dows, doors and vents.
can accumulate.  The fuel supply system is leak-free.
 The generator set is securely mounted.  The engine coolant and raw water systems are
 There is adequate clearance for conducting all leak-free.
maintenance specified in the Operator’s Manu-  The engine has the proper levels of oil and cool-
al. ant.
 The coolant recovery tank is mounted properly  The raw water pump has been primed and the
and is accessible for inspection and filling. sea cock is open.

 The entire exhaust system is accessible for in-  All operators have been thoroughly briefed on
spection and replacement. the Operator’s Manual and its safety precau-
tions—especially concerning the dangers of
 Fuel tanks, piping, hoses and filters comply Carbon Monoxide—and can demonstrate how
with regulations and are accessible for inspec- to operate, maintain and troubleshoot the gen-
tion and replacement. erator set as explained therein.

9-1
10. Specifications

GENERATOR: 2-Bearing, 2-Pole Rotating Field, Microprocessor Regulated. Rating on Generator Set Nameplate
FUEL CONSUMPTION:
60 Hz: Full Load 0.55 gph (2.1 liter/hr)
Half Load 0.35 gph (1.3 liter/hr)
50 Hz: Full Load 0.44 gph (1.7 liter/hr)
Half Load 0.28 gph (1.0 liter/hr)
Engine/Generator Speed: 60 Hz 2900/3600 rpm
50 Hz 2400/3000 rpm
ENGINE: 4-Stroke Cycle, Indirect Injection Diesel, Water Cooled, Microprocessor Governed (Isochronous)
Number of Cylinders 2
Bore 2.64 inch (67 mm)
Stroke 2.68 inch (68 mm)
Displacement 29.23 inch3 (479 cm3)
Compression Ratio 23.5:1
Firing Order (Clockwise Rotation) 1-2
Fuel Injection Timing 18.25 − 19.75 BTDC
Fuel Injection Pressure 1991 psi (13.73 MPa)
Valve Lash (cold) 0.0059 − 0.0073 INCH (0.145 − 0.185 MM)
Engine Oil Capacity 2.2 quart (2.1 liter)
Engine Oil Drain Connection 3/8 NPT
Coolant Capacity 2.2 quart (2.1 liter)
Coolant Flow: 60 Hz 3.5 gpm (13 liter/min)
50 Hz 3.0 gpm (16 liter/min)
Raw Water Flow: 60 Hz 5.0 gpm (19 liter/min)
50 Hz 4.0 gpm (15 liter/min)
Maximum Raw Water Pump Lift 4 feet (1.2 m) with 5/8 inch ID hose
Raw Water Inlet Connection 5/8 inch (15.9 mm) ID Hose
Maximum Fuel Pump Lift 4 feet (1.2 m) with 3/8 inch ID fuel line
Recommended Fuel Line Size 3/8 inch (9 mm) ID
Fuel Supply Connection 1/8 NPT female
Fuel Return Connection 1/8 NPT female
Maximum Exhaust Back Pressure 3 INCH (76 MM) HG
Wet Exhaust Outlet Connection 2.0 INCH (50.8 MM) ID HOSE
Combustion Air 18 CFM (30 M3/HR)
Maximum Angularity 20 Contionuous, 30 Intermittent
Generator Cooling Air 60-80 CFM (100-135 M3/HR)
BATTERIES:
Nominal Battery Voltage 12 volts
Minimum CCA Rating 360 amps
Battery Charging Output Trickle (3 amps)
SIZE, WEIGHT, NOISE:
Size: L x W x H 26 x 20.1 x 20.6 inch (662 x 511 x 524 mm)
Weight (dry) 365 lbs (166 kg)
Noise: 60 Hz 71 dB(A)
50 Hz 68 dB(A)

10-1
 0098-8371

WIRING DIAGRAM

A-1
 0098-8374

GENERATOR CONNECTION DIAGRAM

A-2
 0500−4718

OUTLINE DRAWING

A-3
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email www.cumminsonan.com/contact
www.cumminsonan.com
Cummins , Onan , the “C” logo, and “Performance you rely on.”
are trademarks of Cummins Inc.
 2010 Cummins Power Generation, Inc. All rights reserved.