Installation Manual

Marine Generator Set

MDKAV (Spec A−C)

MDKAW (Spec A−C)
MDKAZ (Spec A−C)
MDKBD (Spec A−B)
MDKBE (Spec A−B)
MDKBF (Spec A−B)
MDKBG (Spec A−C)

English
Original Instructions 7-2013 981−0630 (Issue 4)
“Intentionally Left Blank”

58
Table of Contents
SECTION PAGE

TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . III
GENERAL PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
GENERATOR VOLTAGE IS DEADLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
ENGINE EXHAUST IS DEADLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
Diesel fuel is combustible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
BATTERY GAS IS EXPLOSIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY or death . . . . . . . . . . . . . . . . . . . iv
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . V
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Standards for Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Outline Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
LOCATION AND MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Carbon Monoxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ENGINE COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cooling System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Raw Water Pickup Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
ENGINE EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wet Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Exhaust Water Separator Backflow Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Dry Exhaust Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

i
 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DC Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Fire Suppression System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
FREQUENCY AND VOLTAGE ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Frequency Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Voltage Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
INSTALLATION CHECKS AND STARTUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

INSTALLATION REFERENCE DRAWINGS PAGE

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

RECONNECTION DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
MDKAV OUTLINE DRAWING (WITH ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
MDKAV OUTLINE DRAWING (WITHOUT ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
MDKAW & MDKAZ OUTLINE DRAWING (WITH ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5
MDKAW & MDKAZ OUTLINE DRAWING (WITHOUT ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . A-6
MDKBD & MDKBE OUTLINE DRAWING (WITH ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
MDKBD & MDKBE OUTLINE DRAWING (WITHOUT ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
MDKBD & MDKBE OUTLINE DRAWING (WITH PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
MDKBF OUTLINE DRAWING (WITH ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
MDKBF OUTLINE DRAWING (WITHOUT ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
MDKBF OUTLINE DRAWING (WITH PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
MDKBG OUTLINE DRAWING (WITHOUT ENCLOSURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13

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Safety Precautions
Thoroughly read the OPERATOR’S MANUAL  Make sure all fasteners are secure and proper-
before operating the genset. Safe operation and ly torqued.
top performance can only be attained when  Do not work on the genset when mentally or
equipment is operated and maintained properly. physically fatigued or after having consumed
alcohol or drugs.
The following symbols in this manual alert you to po-
tential hazards to operators, service personnel and  You must be trained and experienced to make
equipment. adjustments while the genset is running—hot,
moving or electrically live parts can cause se-
alerts you to an immediate hazard vere personal injury or death.
that will result in severe personal injury or  Used engine oil has been identified by some
death. U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest,
WARNING alerts you to a hazard or unsafe inhale, or contact used oil or its vapors.
practice that can result in severe personal injury
or death.  Ethylene glycol, used as engine antifreeze, is
toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accor-
CAUTION alerts you to a hazard or unsafe dance with local environmental regulations.
practice that can result in personal injury or
equipment damage.  Keep multi-class ABC fire extinguishers handy.
Class A fires involve ordinary combustible ma-
Electricity, fuel, exhaust, hot engine coolant, moving terials such as wood and cloth; Class B fires,
parts and batteries present hazards which can re- combustible and flammable liquid fuels and
sult in severe personal injury or death. gaseous fuels; Class C fires, live electrical
equipment. (ref. NFPA No. 10)
GENERAL PRECAUTIONS  Genset installation and operation must comply
with all applicable local, state and federal codes
 Keep children away from the genset.
and regulations.
 Do not step on the genset when entering or
leaving the generator room. Parts can bend or GENERATOR VOLTAGE IS DEADLY
break leading to electrical shorts or to fuel, cool-  Generator electrical output connections must
ant or exhaust leaks. be made by a trained and experienced electri-
 To prevent accidental or remote starting while cian in accordance with applicable codes.
working on the genset, disconnect the nega-  The genset must not be connected to shore
tive (−) battery cable at the battery. power or to any other source of electrical pow-
 Let the engine cool down before removing the er. Back-feed to shore power can cause electric
coolant pressure cap or opening the coolant shock resulting in severe personal injury or
drain. Hot coolant under pressure can spray death and damage to equipment. An approved
and cause severe burns. switching device must be used to prevent inter-
connections.
 Do not use evaporative starting fluids. They are
 Use caution when working on live electrical
highly explosive.
equipment. Remove jewelry, make sure cloth-
 Keep the genset, drip pan and compartment ing and shoes are dry, stand on a dry wooden
clean. Oily rags can catch fire. Gear stowed in platform or rubber insulating mat and use tools
the compartment can restrict cooling. with insulated handles.

iii
 ENGINE EXHAUST IS DEADLY BATTERY GAS IS EXPLOSIVE
 Never sleep in the boat while the genset is run-  Wear safety glasses while servicing batteries
ning unless the boat is equipped with properly and do not smoke.
working carbon monoxide detectors.  To reduce arcing when disconnecting or recon-
 The exhaust system must be installed in accor- necting battery cables, always disconnect the
dance with the genset Installation Manual and negative (−) battery cable first and reconnect it
be free of leaks. last.
 Make sure the bilge is adequately ventilated MOVING PARTS CAN CAUSE SEVERE
with a power exhauster. PERSONAL INJURY OR DEATH
 Inspect for exhaust leaks every startup and af-  Do not wear loose clothing or jewelry near mov-
ter every eight hours of operation. ing parts such as PTO shafts, fans, belts and
 For more information about carbon monoxide pulleys.
see American Boat and Yacht Council (ABYC)  Keep hands away from moving parts.
publication TH-22—Educational Information
 Keep guards in place over fans, belts, pulleys,
About Carbon Monoxide.
and other moving parts.
DIESEL FUEL IS COMBUSTIBLE FLAMMABLE VAPOR ENVIRONMENT
 Do not smoke or turn electrical switches ON or
Flammable vapor can cause a diesel engine to
OFF where fuel fumes are present or in areas
overspeed and become difficult to stop, resulting in
sharing ventilation with fuel tanks or equip-
possible fire, explosion, severe personal injury or
ment. Keep flames, sparks, pilot lights, arc-pro-
death. Do not operate a diesel-powered genset
ducing equipment and all other sources of igni-
in a flammable vapor environment created by
tion well away.
fuel spill, leak, etc. The owners and operators of
 Fuel lines must be secured, free of leaks and the genset are solely responsible for operating the
separated or shielded from electrical wiring. genset safely.

POST THESE SUGGESTIONS IN POTENTIAL HAZARD AREAS OF THE BOAT

M-10

iv
Specifications
MDKAV MDKBG MDKAW MDKAZ
ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.
Alternator Cooling Air Flow: 60 Hz 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min)
50 Hz 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min)
FUEL CONSUMPTION:
60 Hz: Full Load 0.8 gph (3.0 liter/hr) 0.8 gph (3.0 liter/hr) 1.0 gph (3.8 liter/hr) 1.2 gph (4.5 liter/hr)
Half Load 0.5 gph (1.9 liter/hr) 0.5 gph (1.9 liter/hr) 0.6 gph (2.3 liter/hr) 0.7 gph (2.7 liter/hr)
50 Hz: Full Load 0.7 gph (2.7 liter/hr) 0.7 gph (2.7 liter/hr) 0.8 gph (3.0 liter/hr) 0.9 gph (3.4 liter/hr)
Half Load 0.4 gph (1.5 liter/hr) 0.4 gph (1.5 liter/hr) 0.5 gph (1.9 liter/hr) 0.5 gph (1.9 liter/hr)
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing
Model D1105 D1105 V1305 V1505
Number of Cylinders 3 3 4 4
Displacement 68.58 in3 (1124 cm3) 68.58 in3 (1124 cm3) 81.47 in3 (1335 cm3) 91.44 in3 (1499 cm3)
Bore 3.07 in (78 mm) 3.07 in (78 mm) 2.99 in (76 mm) 3.07 in (78 mm)
Stroke 3.09 in (78.4 mm) 3.09 in (78.4 mm) 2.90 in (73.6 mm) 3.09 in (78.4 mm)
Compression Ratio 22:1 22:1 22:1 22:1
Firing Order (Clockwise Rotation) 1-2-3 1-2-3 1-2-4-3 1-2-4-3
Fuel Injection Timing 15.5 − 17.5 BTDC 15.5 − 17.5 BTDC 15.5 − 17.5 BTDC 15.5 − 17.5 BTDC
0.0071 − 0.0087 in 0.0071 − 0.0087 in 0.0071 − 0.0087 in 0.0071 − 0.0087 in
Valve Lash (cold) (0.18 − 0.22 mm) (0.18 − 0.22 mm) (0.18 − 0.22 mm) (0.18 − 0.22 mm)
Lube Oil Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 4.5 quart (4.3 liter) 4.5 quart (4.3 liter)
Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT 3/8 NPT
Coolant Capacity 4.2 quart (4.0 liter) 4.2 quart (4.0 liter) 5.3 quart (5.0 liter) 5.3 quart (5.0 liter)
Coolant Flow Rate: 60 Hz 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9liter/min)
50 Hz 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min) 4.2 gpm (15.9 liter/min)
Raw Water Flow Rate: 60 Hz 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min) 6.0 gpm (22.7 liter/min)
50 Hz 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min) 5.0 gpm (18.9 liter/min)
Combustion Air Flow: 60 Hz 30 cfm (0.85 m3/min) 30 cfm (0.85 m3/min) 36 cfm (1.02 m3/min) 41 cfm (1.16 m3/min)
50 Hz 25 cfm (0.71 m3/min) 25 cfm (0.71 m3/min) 30 cfm (0.85 m3/min)) 34 cfm (0.96 m3/min)
Heat Rejection to Ambient: 60 Hz 200 Btu/min (50 kcal/min) 200 Btu/min (50 kcal/min) 230 Btu/min (58 kcal/min) 280 Btu/min (71 kcal/min)
50 Hz 179 Btu/min (45 kcal/min) 179 Btu/min (45 kcal/min) 190 Btu/min (48 kcal/min) 210 Btu/min (53 kcal/min)
CONNECTIONS:
Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)
Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female
Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female 1/4 NPT female
Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)
Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
KEEL COOLING AND DRY EXHAUST:
Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)
Heat Rejection to Coolant: 60 Hz 950 Btu/min (239 kcal/min) 950 Btu/min (239 kcal/min) 1220 Btu/min (307 kcal/min) 1420 Btu/min (358 kcal/min)
50 Hz 780 Btu/min (197 kcal/min) 780 Btu/min (197 kcal/min) 980 Btu/min (247 kcal/min) 1160 Btu/min (292 kcal/min)
Dry Exhaust Outlet 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT 1-1/4 NPT
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts* 12 volts* 12 volts*
Min CCA Rating − SAE @ 32 F (0 C) 360 amps 360 amps 500 amps 500 amps
Battery Charging 5 amps 5 amps 5 amps 5 amps
SIZE, WEIGHT, NOISE:
Without Enclosure
Dry Weight 555 lbs (252 kg) 525 lbs (238 kg) 640 lbs (290 kg) 640 lbs (290 kg)
Dimensions: L x W x H 35.9 x 22.3 x 23.0 in 32.4 x 18.9 x 22.1 in 40.7 x 22.3 x 23.0 in 40.7 x 22.3 x 23.0 in
(911 x 566 x 585 mm) (479.1 x 822.6 x 560.9 mm) (1033 x 566 x 585 mm) (1033 x 566 x 585 mm)
With Enclosure
Noise 66 dB(A) @ 60HZ − 66 dB(A) @ 60HZ 66 dB(A) @ 60HZ
Dry Weight 600 lbs (272 kg) 695 lbs (315 kg) 695 lbs (315 kg)
Dimensions: L x W x H 35.9 x 22.3 x 23.4 in 40.7 x 22.3 x 23.4 in 40.7 x 22.3 x 23.4 in
(911 x 566 x 593 mm) (1033 x 566 x 593 mm) (1033 x 566 x 593 mm)
* - 24 volts optional

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 MDKBD MDKBE MDKBF
ALTERNATOR: Single-Bearing, Brushless 4-Pole Rotating Field with Digital Electronic Regulation. See Genset Nameplate for Rating.
Alternator Cooling Air Flow: 60 Hz 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min) 275 cfm (0.85 m3/min)
50 Hz 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min) 230 cfm (0.71 m3/min)
FUEL CONSUMPTION:
60 Hz: Full Load 1.3 gph (4.9 liter/hr) 1.9 gph (7.2 liter/hr) 2.5 gph (9.5 liter/hr)
Half Load 0.8 gph (3.0 liter/hr) 1.1 gph (4.2 liter/hr) 1.5 gph (5.7 liter/hr)
50 Hz: Full Load 1.1 gph (4.2 liter/hr) 1.6 gph (6.1 liter/hr) 2.1 gph (8.0 liter/hr)
Half Load 0.7 gph (2.7 liter/hr) 0.9 gph (3.4 liter/hr) 1.3 gph (4.9 liter/hr)
ENGINE: Kubota 4-Stroke Cycle, Indirect Injection, Water Cooled Diesel with Digital Electronic Governing
Model V1903B V2203B V2803B
Number of Cylinders 4 4 5
Displacement 113.37 in3 (1857 cm3) 134.07 in3 (2197cm3) 167.57 in3 (2748 cm3)
Bore 3.15 in (80 mm) 3.43 in (87 mm) 3.43 in (87 mm)
Stroke 3.64 in (92.4 mm) 3.64 in (92.4 mm) 3.64 in (92.4 mm)
Compression Ratio 23:1 23:1 23:1
Firing Order (Clockwise Rotation) 1-3-4-2 1-3-4-2 1-3-5-4-2
Fuel Injection Timing 15.5 − 17.5 BTDC 15.5 − 17.5 BTDC 15.5 − 17.5 BTDC
0.0071 − 0.0087 in 0.0071 − 0.0087 in 0.0071 − 0.0087 in
Valve Lash (cold) (0.18 − 0.22 mm) (0.18 − 0.22 mm) (0.18 − 0.22 mm)
Lube Oil Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 12.7 quart (12 liter)
Lube Oil Drain Connection 3/8 NPT 3/8 NPT 3/8 NPT
Coolant Capacity 8 quart (7.6 liter) 8 quart (7.6 liter) 8 quart (7.6 liter)
Coolant Flow Rate: 60 Hz 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min) 14.0 gpm (53.0 liter/min)
50 Hz 10.0 gpm (37.9 liter/min) 10.0 gpm (37.9 liter/min)) 10.0 gpm (37.9 liter/min)
Raw Water Flow Rate: 60 Hz 9.0 gpm (34.1 liter/min) 9.0 gpm (34.1 liter/min) 9.0 gpm (34.1 liter/min)
50 Hz 7.0 gpm (26.5 liter/min) 7.0 gpm (26.5 liter/min) 7.0 gpm (26.5 liter/min)
Combustion Air Flow: 60 Hz 52 cfm (1.45 m3/min) 60 cfm (1.72 m3/min) 41 cfm (1.16 m3/min)
50 Hz 42 cfm (1.21 m3/min) 50 cfm (1.43 m3/min)) 34 cfm (0.96 m3/min)
Heat Rejection to Ambient: 60 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
50 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
CONNECTIONS:
Max Fuel Pump Lift 4 ft (1.2 m) 4 ft (1.2 m) 4 ft (1.2 m)
Fuel Supply 1/4 NPT female 1/4 NPT female 1/4 NPT female
Fuel Return 1/4 NPT female 1/4 NPT female 1/4 NPT female
Max Raw Water Pump Lift 4 ft (1.22 m) 4 ft (1.22 m) 4 ft (1.22 m)
Raw Water Inlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Wet Exhaust Outlet 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose 2 in (50.8 mm) ID Hose
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
KEEL COOLING AND DRY EXHAUST:
Coolant Inlet & Outlet 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose 1 in (25.4 mm) ID Hose
Max Coolant Friction Head 1 psi (6.9 kPa) 1 psi (6.9 kPa) 1 psi (6.9 kPa)
Heat Rejection to Coolant: 60 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
50 Hz Btu/min ( kcal/min) Btu/min (kcal/min) Btu/min (kcal/min)
Dry Exhaust Outlet 1-1/2 NPT 1-1/2 NPT 1-1/2 NPT
Max Exhaust Back Pressure 3 in (76 mm) Hg 3 in (76 mm) Hg 3 in (76 mm) Hg
BATTERIES:
Nominal Battery Voltage 12 volts* 12 volts* 12 volts*
Min CCA Rating − SAE @ 32 F (0 C) 500 amps 625 amps 625 amps
Battery Charging 5 amps 5 amps 5 amps
SIZE, WEIGHT, NOISE:
Without Enclosure
Dry Weight 830 lbs (377 kg) 870 lbs (375 kg) 1090 lbs (494 kg)
Dimensions: L x W x H 44.4 x 23.7 x 26.1 in 44.4 x 23.7 x 26.1 in 53.5 x 23.7 x 28.8 in
(1127 x 602 x 663 mm) (1127 x 602 x 663 mm) (1358 x 602 x 732 mm)
With Enclosure
Noise 67/64 dB(A) @ 60/50 HZ 67/64 dB(A) @ 60/50 HZ 67/66 dB(A) @ 60/50 HZ
Dry Weight 890 lbs (404 kg) 930 lbs (422 kg) 1175 lbs (533 kg)
Dimensions: L x W x H 44.4 x 23.7 x 27.5 in 44.4 x 23.7 x 27.5 in 53.5 x 23.7 x 30.0 in
(1127 x 602 x 698 mm) (1127 x 602 x 698 mm) (1358 x 602 x 763 mm)
* - 24 volts optional

vi
Introduction
A generator set (genset) must be installed properly typical regulatory agency. It is suggested that you
to attain safe, reliable and quiet operation. Read obtain the following standards:
through this manual completely before starting the  Standards and Recommended Practices For
installation. It is a guide only. You must decide how Small Craft,
to address the particular concerns of the installa-
tion. American Boat and Yacht Council, Inc.
P.O. Box 747
Decisions you have to make will concern: Millersville, MD 21108
 Location and mounting  NFPA No. 302, Pleasure and Commercial Mo-
tor Craft,
 Engine exhaust discharge and silencing
National Fire Protection Association
 Engine cooling Batterymarch Park
 Genset room ventilation Quincy, MA 02269
 USCG regulations are under Titles 33 and 46 of
 Fuel connections
the Code of Federal Regulations (CFR),
 Batteries U.S. Government Printing Office
 Electrical connections Washington, D.C. 20404.
 Bonding for grounding Boats used in U. S. waters must comply with
 Accessibility for operation and maintenance ABYC P-1, Installation of Exhaust Systems for Pro-
pulsion and Auxiliary Machinery; ABYC E-8, Alter-
 Noise and vibration. nating Current (AC) Electrical Systems on Boats;
and ABYC E-9, Direct Current (DC) Electrical Sys-
See the Operator’s Manual for operation and main- tems on Boats.
tenance and the Service Manual for service.
OUTLINE DRAWINGS
Note: Manuals are updated from time-to-time to re-
flect changes in the equipment and its specifica- See the applicable OUTLINE DRAWING (begin-
tions. For this reason, only the copy of the installa- ning Page A-3) for installation details: mounting bolt
tion manual supplied with the genset should be used hole locations, connection points (fuel, battery, raw
as a guide for the installation. water, exhaust, remote control and AC output),
sizes and types of fittings, weight, overall dimen-
STANDARDS FOR SAFETY sions, etc. See your Onan dealer for a large-scale
copy of the applicable drawing.
You must find out which standards for safety are ap-
plicable. The American Boat and Yacht Council WARNING Improper installation can result in
(ABYC) and the National Fire Protection Associa- severe personal injury or death and damage to
tion (NFPA) are typical of agencies that publish equipment. The installer must be trained and ex-
safety standards for the installation of marine equip- perienced in the installation of electrical, me-
ment. The United States Coast Guard (USCG) is a chanical, fuel and exhaust equipment.

1
This page is intended to be blank.

2
Location and Mounting
The genset has a single lifting eye which is accessi- (100 mm) of clearance for air flow in and the right
ble through an access cover if the genset has an en- side at least 2 inches (5 mm) for air flow out (OUT-
closure. See Specifications (Page v) regarding the LINE DRAWINGS, beginning Page A-3).
weight of the genset and make provisions accord-
ingly for safe handling. Make sure there is access for:
 Starting and stopping the genset
LOCATION  Resetting the line circuit breakers
See the other sections titled Ventilation, Fuel Sup-  Checking, filling and draining engine oil
ply, Engine Cooling and Engine Exhaust for addi-
tional considerations that bear on location.  Changing the engine oil filter
 Checking, filling and draining engine coolant
The genset is not “ignition protected” and therefore
not permitted under USCG regulation 33CFR183 to  Changing the fuel filter
be located in a gasoline fuel environment. If the boat  Making fuel connections
has gasoline-fueled propulsion engines, the genset
will have to be located where it can be isolated from  Making battery and ground connections
the gasoline fuel system by approved methods.  Replacing coolant and exhaust hoses
WARNING The genset can ignite gasoline  Replacing the raw water pump impeller
fumes causing severe personal injury or death.  Adjusting the V-belt
Approved methods must be used to isolate the
genset from a gasoline fuel environment.
MOUNTING
Because of noise, vibration and fumes, the genera-
tor compartment should be located as far from living The genset has integral vibration isolators. The sup-
quarters as practical. porting structure underneath should be level and
able to support the weight of the genset. Floor or
Locate the genset where there will be enough room frame stiffness should be greatest under the vibra-
to perform periodic maintenance and service. Non- tion isolators. Secure the genset with four bolts. See
service sides should have at least 2 inches (50 mm) the appropriate OUTLINE DRAWING (beginning
of clearance. The front should have at least 4 inches Page A-3) for the mounting bolt hole locations.

3
This page is intended to be blank.

4
Ventilation
WARNING EXHAUST GAS IS DEADLY—FUEL Use 40 in2 (258 cm2) as the basis for calculations for
VAPORS ARE EXPLOSIVE! Failure to provide inlet and outlet air duct sizes and free-air areas of
proper ventilation can result in asphyxiation, screens and louvers. Do not use flush air inlets or
fire and explosion. The ventilation system must louvered transom outlets, which are easily blocked.
meet applicable standards and regulations, in-
The USCG requires power exhausters, which may
cluding ABYC, NFPA and USCG (Page 1).
also be necessary for genset cooling, especially just
VENTILATION after the boat has been under way. Operating a gen-
set in ambient temperatures above 104 F (40 C)
Ventilation is required to prevent dangerous con- will result in noticeable loss of power. Operating a
centrations of fuel vapors and exhaust fumes, hold genset in ambient temperatures higher than 122 F
down compartment temperatures and provide com- (50 C) will reduce the life of electrical components,
bustion air. See Table 1 for minimum U.S. Coast generator windings, rubber and other construction
Guard requirements for ventilating fuel and exhaust materials.
fumes in passenger boats.
CARBON MONOXIDE
TABLE 1. MINIMUM USCG AIR EXCHANGE RATES
FOR VENTILATING FUEL AND EXHAUST FUMES All openings and feed-through holes for wiring, con-
MAXIMUM TIME TO duit, pipe and hose must be sealed to prevent ex-
COMPARTMENT SIZE EXCHANGE TOTAL AIR haust gases from entering the rest of the boat. Wir-
Cubic Feet (m3) VOLUME (Minutes) ing conduit must be sealed inside as well as outside.
Less than 500 (14) 2
500 to 1000 (14 to 29) 3 Cabin plumbing drains must have approved traps to
1000 to 1500 (28 to 42) 4 prevent the entrance of exhaust gases from outside.
1500 and Up (42 and Up) 5
Carbon monoxide (CO) detectors, listed for marine
To promote natural convective flow, good air ex- applications, should be installed in the living quar-
change and fresh air for combustion and generator ters of the boat. Wind shifts, boat motion, exhaust
cooling, ventilating air should enter near the bottom from other boats at dockside and other conditions
of the compartment at the front near the air inlet and can cause exposure to harmful concentrations of
exit near the top at the right side (OUTLINE DRAW- carbon monoxide even when proper ventilation is
INGS, beginning Page A-3). The free-air area of the provided and living quarters are sealed off from en-
inlet air cowl should be at least twice that of the duct. gine rooms.

5
This page is intended to be blank.

6
Fuel Supply
WARNING Diesel fuel is combustible and can nect it to a large distribution manifold that the genset
cause severe personal injury or death due to fire lift pump would have to prime.
or explosion. Fuel tank construction, location,
installation, bonding for grounding, ventilation, Use non-conductive fuel lines for connections at the
piping, inspection and leak testing must be in genset to prevent the fuel lines from carrying crank-
accordance with applicable standards and reg- ing currents back through the fuel tank. Fuel tanks
ulations, including ABYC, NFPA and USCG are required to be bonded to the common nega-
(Page 1). tive (−) grounding system of the boat.

Fuel: See the Operator’s Manual for recommended WARNING Fuel lines must not carry cranking
fuel. currents, which can cause fire resulting in se-
vere personal injury or death. Use non-conduc-
Fuel Filters: The genset is equipped with a water tive fuel lines for connections at the genset.
separator type of fuel filter accessible for periodic
draining of water and sediment and replacement. Fuel Pickup: The recommended inside diameter
The fuel supply system should also be equipped for the fuel pickup tube is 5/16 inch (8 mm). A larger
with a fuel filter and water separator ahead of the diameter tube will drain down more readily.
connections at the genset. Keep out dirt and debris
when making fuel connections. In a common fuel supply tank, the genset pickup
tube should be shorter than those for the propulsion
Fuel Fittings: Two 1/4 NPT fittings for fuel supply engines so that the genset cannot empty the fuel
and return connections are mounted on one end of tank. Make sure the fuel tanks are large enough to
the genset or the other. See the appropriate OUT- cool the returning fuel.
LINE DRAWING (beginning Page A-3). To connect
fuel hose, use hose adapter fittings at the 1/4 NPT Fuel Lift: The fuel lift pump mounted in the genset
fittings on the genset. These are available from can handle up to 4 feet (1.2 m) of fuel suction head
Onan. (combination of lift height and line friction) in
5/16 inch fuel line.
Fuel Lines and Hoses: Use USCG TYPE A1 or
ISO 7840-A1 fuel hose. The recommended inside If the highest level of fuel in the fuel supply tank is
diameter for fuel lines and hoses is 5/16 inch higher than the fuel injectors, an approved method
(8 mm). Larger diameter fuel lines take longer to must be used to prevent flow when the engine is not
prime and drain down more readily, allowing air to running.
enter. Smaller diameter fuel lines may restrict flow
CAUTION Do not use galvanized fuel tanks, fit-
enough to affect engine performance.
tings and pipes. Sulfur in diesel fuel attacks the
To avoid starving the genset for fuel, do not have it galvanized (zinc) coat causing debris that can
share fuel lines with the propulsion engines or con- clog fuel filters, pumps and injectors.

7
This page is intended to be blank.

8
Engine Cooling
COOLING SYSTEM OVERVIEW for best flow when the boat is under way. Also, stag-
ger the through-hull fittings along the keel so that
The engine is cooled by a pressurized, closed-loop downstream fittings are not starved.
liquid cooling system (Figure 1 or 2). Coolant is
pumped through passages in the engine block, CAUTION Do not use a scoop-type through-
head and exhaust manifold by a belt-driven pump hull fitting. A forward-facing scoop can develop
and is cooled in a heat exchanger mounted on the enough ram pressure to flood the engine. A
base pan or in a keel cooler. rear-facing scoop can develop enough suction
to impede flow.
If the genset has a heat exchanger and/or exhaust-
water mixer, the engine is equipped with a gear-driv- Siphon-Break: Conduct the RAW WATER PICKUP
en raw water pump. The raw water cools the heat TEST and install a siphon-break device (Figure 4)
exchanger and/or exhaust gases and exits the boat between the engine heat exchanger and exhaust-
through the exhaust system. water mixer (Figure 1 or 2) if required. The top panel
of an enclosed genset has knockouts for the hoses
SYSTEM COMPONENTS to pass through. See the appropriate OUTLINE
DRAWING (beginning Page A-3).
Raw water Pump: The raw water pump can handle
up to 4 feet (1.2 m) of suction head (combination of A siphon-break kit is available from Onan. The kit
lift height and hose friction) in 1 inch (25.4 mm) has hole grommets.
hose. The pump impeller must be wetted with water
to establish initial pump lubrication and suction. See CAUTION Failure to install a siphon-break de-
the Operator’s Manual. vice, when required, can cause major engine
damage if the cylinders become flooded.
Raw Water Hose: The 1 inch (25.4 mm) hose barb
for raw water pickup is mounted on one end of the Coolant Recovery Tank: The genset is shipped
genset or the other. See the appropriate OUTLINE with a coolant recovery tank kit. Follow the instruc-
DRAWING (beginning Page A-3). Use SAE 20R3 tions in the kit. The tank must be accessible for
or equivalent hose to supply raw water to the gen- daily inspection and refilling. Clamp the recovery
set. The hose must be able to resist a slight vacuum. hose to the hose barb on the coolant fill neck
(Page 10). Route hose through the hole in the right
Sea Water Strainer: The sea water strainer should end of the enclosure. The end panel on an enclosed
have a 1 inch (25.4 mm) inlet. It should be located genset has holes for mounting the recovery tank.
below the raw water pump and as close as possible. See the appropriate OUTLINE DRAWING (begin-
The basket must be removeable for cleaning. ning Page A-3). Fill the tank in accordance with the
Operator’s Manual.
Sea Cock: Install a bronze, full-flow sea cock on the Initial Coolant Fill: The genset is normally shipped
through-hull fitting. from the factory with coolant, unless prohibited by
shipping regulations. Fill the system, if necessary, in
Through-Hull Fitting and Strainer: The through- accordance with the Operator’s Manual.
hull fitting should have a 1 inch (25.49 mm) inlet and
be as close to the genset as possible. The slots in CAUTION Running the genset without cool-
the strainer on the fitting must be parallel to the keel ant will severely damage the engine.

9
 OPTIONAL LOW COOLANT
LEVEL SENSOR LOCATION

COOLANT THERMOSTAT

COOLANT PUMP

RAW WATER PUMP

RAW WATER FLOW SENSOR

RAW WATER IN FROM

BULKHEAD FITTING ON EXHAUST MANIFOLD & COOLANT RESERVOIR
RIGHT OR LEFT SIDE WITH PRESSURE CAP AND COOLANT FILL
NECK. FILL NECK HAS HOSE BARB FOR
CONNECTING COOLANT RECOVERY TANK

EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT OR
LEFT SIDE

WHEN REQUIRED,
REMOVE THIS HOSE AND
INSTALL A SIPHON BREAK
(PAGE 9)

BLOCK DRAIN COCK

(COOLANT)

COOLANT RAW WATER CLEANOUT

DRAIN COCK COVER (BOTH ENDS)
COOLANT
ZINC RAW WATER DRAIN
ANODE PLUG RAW WATER
(BOTH ENDS)

FIGURE 1. ENGINE COOLING SYSTEM—MDKAV, MDKBG, MDKAW, MDKAZ

10
 RAW WATER TO PUMP FROM COOLANT RESERVOIR WITH PRESSURE CAP AND
BULKHEAD FITTING ON COOLANT FILL NECK. FILL NECK HAS HOSE BARB
RIGHT OR LEFT SIDE FOR CONNECTING COOLANT RECOVERY TANK

LOCATION, OPTIONAL LOW

COOLANT LEVEL SENSOR

COOLANT
THERMOSTAT
HOUSING

COOLANT
TEMPERATURE
SENSOR
RAW
WATER
PUMP
COOLANT
PUMP PULLEY

WHEN REQUIRED,
REMOVE THIS HOSE AND LOCATION, BLOCK
INSTALL A SIPHON BREAK DRAIN COCK
(PAGE 9) (COOLANT)

RAW WATER FLOW SWITCH

(IN PUMP-TO-HEAT EXCHANGER HOSE) ZINC ANODE

EXHAUST-WATER MIXER
WITH HIGH TEMPERATURE
EXHAUST SWITCH

EXHAUST & RAW WATER OUT

TO BULKHEAD FITTING ON RIGHT
OR LEFT SIDE

RAW WATER CLEANOUT COVER

COOLANT DRAIN COCK (BOTH ENDS—MAKE SURE TO COOLANT
& RAW WATER PLUGS RECONNECT GROUND STRAP ON
(UNDERNEATH) THIS END WITH COVER SCREW) RAW WATER

FIGURE 2. ENGINE COOLING SYSTEM—MDKBD, MDKBE, MDKBF

11
 RAW WATER PICKUP TEST while operating the boat throughout its speed range.
Also mark the water line while the boat is docked.
Objective: To determine the elevation of the water
line relative to the genset under all operating condi- Requirement: If either water line (docked or under
tions. way) is within 6 inches (152 mm) of the engine ex-
Method: Load the boat fully for the sea trials, shut haust-water mixer:
down the genset and disconnect the raw water pick- 1. Install a siphon-break device, or
up hose from the genset bulkhead fitting (OUTLINE
DRAWING beginning Page A-3). (Be ready to close 2. If the water line while docked is 6 inches
the sea cock, if necessary, and to catch water that (152 mm) or more below the exhaust-water
spills.) Raise and lower the end of the hose. The wa- mixer but the water line under way is above, it
ter line is at the level where water just begins to spill may be possible to take steps to lower the latter.
as the end of the hose is slowly lowered. (Alterna- For example, a forward-facing scoop-type
tively, for this test only, connect a clear plastic hose through-hull fitting might be causing the differ-
to the through-hull fitting or strainer so that you can ence. If so, replace it with a through-hull fitting
see the water level rise and fall inside the hose.) that does not create ram pressure when the
Mark on the genset the highest water line observed boat is under way.

12
Engine Exhaust
WET EXHAUST SYSTEMS The base of the muffler should not be more than
54 inches (1.4 meter) below the water separator
WARNING EXHAUST GAS IS DEADLY! The ex- (Figure 3) or 48 inches (1.2 meter) below the crest
haust system must be leak-free and convey all in the piping (Figure 4).
exhaust outside, away from windows, doors
and vents. Mount the muffler such that air can circulate under-
neath to prevent condensation and mold.
Figure 3 illustrates a typical exhaust system where
the exhaust-water mixer is above the load water line Exhaust Water Separator: When an exhaust wa-
and Figure 4 where it is below. See Engine Cooling ter separator is used (Figure 3), the muffler outlet
(Page 9) regarding raw water connections. The and water separator inlet diameters must be the
installation must comply with applicable standards same size. The water separator should be installed
and regulations, including ABYC and USCG directly above the muffler to maintain a vertical lift.
(Page 1). The through-hull fitting for the drain hose should be
below the load water line and must have a sea cock.
Kits are available from Onan consisting of an ap- An EXHAUST WATER SEPARATOR BACKFLOW
proved muffler, a water separator or a resonator, or TEST must be conducted during the sea trials to de-
a combination of muffler and water separator or termine that there is no backflow.
muffler and resonator. Muffler kits include a strainer
for the through-hull fitting. A siphon break kit is also Exhaust Through-Hull Fitting: The exhaust
available. through-hull fitting must be above the load water
line. To reduce wave wash-in, the highest point in
Exhaust Hose: Use hose that has been approved the exhaust system must crest at least 12 inches
for wet exhaust systems. Approved hose and 90 de- (305 mm) above the through-hull fitting (Figure 4).
gree elbows of stainless steel tubing are available The top of a water separator (Figure 3) must be at
from Onan. Except where hose rises vertically from least 18 inches (450 mm) above the load water line.
the muffler, hose must slope down at least 1/2 inch CAUTION Backflow can cause major engine
per foot (42 mm/meter) and be supported such that damage if the cylinders become flooded. The
there are no sags. The entire run of hose must be sea trials must verify that there is no backflow
accessible for regular, visual inspections and re- through either the exhaust hull fitting or the wa-
placement. ter separator drain hose fitting.
Hose Clamps: Use two 1/2 inch (12.7 mm) wide Siphon-Break: See Page 9.
stainless steel hose clamps to clamp each end of
each exhaust hose. EXHAUST WATER SEPARATOR
BACKFLOW TEST
Fitting and Hose Diameters: No fitting or hose
section in the exhaust system may have a smaller Objective: To determine that there is no backflow
inside diameter than the engine outlet. If the total through the exhaust water separator under any op-
run of exhaust hose is more than 20 feet (6 meters), erating condition (Figure 3).
measure exhaust back pressure and use larger di- Method: Conduct this test during the sea trials in
ameter hose if back pressure exceeds Specifica- conjunction with the RAW WATER PICKUP TEST.
tions (Page v). Prepare by closing the drain hose sea cock and dis-
connecting the hose from the water separator. Con-
Muffler: Install an approved muffler as close a prac- duct the test by opening the sea cock while keeping
tical to the engine. For optimum silencing, the length the hose raised to its fitting on the water separator.
of hose between the engine and muffler should not
exceed 6 feet (2 meter). The muffler inlet should be Requirement: There must not be any back flow
a minimum of 1 foot (305 mm) below the exhaust- while operating the boat throughout its speed range.
water mixer and the outlet should be vertical. If there is, relocate the through-hull fitting.

13
 INSTALL A WATER SEPARATOR OR FABRI-
CATE A KNEE AS SHOWN IN FIGURE 4 AT
THE HIGHEST POINT IN EXHAUST SYSTEM

WATER-EXHAUST MIXER LEVEL

(SEE APPROPRIATE OUTLINE DRAWING) WATER
SEPARATOR

GENSET
LOAD WATERLINE

14
MUFFLER

SIPHON BREAK REQUIRED

IF LESS THAN 6 IN (152 MM) SEA
RECOMMEND 12 IN (305 MM)
COCK
54 IN (1.4 M) MAXIMUM

18 IN (457 MM) MINIMUM

Notes: ABOVE WATERLINE

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

2. The operator will not be able to look for water discharge from the hull to tell whether engine/exhaust cooling
water is flowing. However, the genset will shutdown if water stops flowing (Code No. 7) or exhaust tempera-
ture rises because of loss of water (Code No. 58). See Troubleshooting in the Operator’s Manual.

FIGURE 3. TYPICAL INSTALLATION ABOVE LOAD WATERLINE—WITH A WATER SEPARATOR

 A SIPHON BREAK IS REQUIRED IF THE WATER- FABRICATE A KNEE AS SHOWN OR INSTALL
EXHAUST MIXER IS BELOW, OR IS LESS THAN A WATER SEPARATOR (FIGURE 3) AT THE
6 IN (152 MM) ABOVE, THE LOAD WATER LINE HIGHEST POINT IN EXHAUST SYSTEM

SIPHON BREAK

12 IN
(305 MM)
MIN

LOAD WATERLINE

15
GENSET

MUFFLER

RECOMMEND 12 IN (305 MM)

WATER-EXHAUST MIXER LEVEL 12 IN (305 MM) MINIMUM

(SEE APPROPRIATE OUTLINE DRAWING)
48 IN (1.2 M) MAXIMUM
Notes:
ABOVE WATERLINE
1. All exhaust hose and pipe must slope, without sagging, at least 1/2 inch per foot (42 mm/meter).

FIGURE 4. TYPICAL INSTALLATION BELOW LOAD WATERLINE—WITH A SIPHON BREAK

 DRY EXHAUST SYSTEMS which should be located where the piping turns to
rise vertically.
Figure 5 shows a typical dry exhaust system. A sep-
arate exhaust system must be provided for each en- Exhaust piping must be routed at least 9 inches
gine. Soot, corrosive condensate and high gas tem- (229 mm) away from combustible construction.
peratures can damage idle engines served by a Where a 9 inch clearance cannot be maintained,
common exhaust system. the pipe may be insulated with material rated to
withstand at least 1000F (538C). The surface
Consult the factory about exhaust pipe routing temperature of the insulation must not exceed
if the genset is equipped with a sound shield. 160F (71C).
The exhaust system must be supported indepen-
Exhaust piping and mufflers must be shielded or in-
dently of the engine. Weight on the engine exhaust
sulated to prevent burns if accidental contact is like-
outlet can crack the exhaust manifold.
ly. The surface of the shield or insulation must not
A flexible, bellows-type stainless steel section at exceed 200F (93C).
least 18 inches (300 mm) long must be connected
at the engine exhaust outlet to take up thermal ex- The entire exhaust system must be accessible for
pansion and engine movement. regular, visual inspection and repair.

Long runs of exhaust pipe (vertical or horizontal) See Specifications for maximum allowable exhaust
should include a flexible, bellows-type stainless back pressure. Application Manual T-030 has ex-
steel section to take up thermal expansion. Flexible ample exhaust back pressure calculations.
exhaust sections must not be used to compensate
for misaligned piping or for forming bends. CAUTION Excessive exhaust back pressure
reduces the air-fuel ratio, resulting in reduced
Horizontal runs of exhaust piping should slope power, excessive smoke, high exhaust temper-
downwards from the engine to a drain trap and plug, ature and reduced engine life.

BOW OF VESSEL

FLEXIBLE
SUPPORT

RIGID MUFFLER
RIGID
SUPPORT SUPPORT

FLEXIBLE
SUPPORTS
FLEXIBLE
PIPE
CONDENSATE
DRAIN TRAP

DRY EXHAUST EL-

BOW AT GENSET

FIGURE 5. SCHEMATIC OF TYPICAL DRY EXHAUST SYSTEM

16
Electrical Connections
WARNING Accidental or remote starting can WARNING Backfeed to shore power can cause
cause severe personal injury or death. To pre- electric shock resulting in severe personal inju-
vent accidental starting, disconnect the nega- ry or death and damage to equipment. Use an
tive (−) battery cable from the battery before approved device to prevent the genset from be-
working on the genset. ing interconnected with shore power.

WARNING HAZARDOUS VOLTAGE! Touching Load Balancing: The currents in the legs of a
uninsulated live parts inside the genset and 2-phase or 3-phase generator should be balanced
connected equipment can result in severe per- within 10 percent. Redistribute the loads as neces-
sonal injury or death. For your protection, stand sary.
on a dry wooden platform or rubber insulating
mat, make sure your clothing and shoes are dry, Make sure to secure the clear protective cover over
remove jewelry from your hands and use tools the AC connections before securing the outer ac-
with insulated handles. cess cover. Make sure the outer cover is turned the
right way so that the opening above the circuit
WARNING Improper wiring can cause fire or breakers is closed off.
electric shock resulting in severe personal inju-
ry or death.

GENERATOR
TURN COVER
Wiring Methods: All wiring methods, connections, SO THAT THIS
wire ampacities, equipment grounding and materi- GAP IS ON OTH-
als must be inspected and comply with applicable ER SIDE, EX-
regulations. Use flexible conduit and stranded con- CEPT FOR
3-PHASE
ductors for load wiring to take up movement and
vibration. See the appropriate OUTLINE DRAW-
ING (beginning Page A-3) for the location of the AC CLEAR PRO-
box and its conduit knockouts. TECTIVE
COVER

Generator Connections: Make generator connec-

tions and reconnections as required in the AC box
INSULATED
(Figure 6) in accordance with the appropriate re- STANDOFF
connection diagram (Page A-2). The circuit break- TERMINAL GROUND
ers may need to be replaced to obtain full genset TERMINAL
power if reconnections are made. Voltage and fre-
quency may also need to be readjusted (Frequency
AC
and Voltage Adjustments, Page 21). BOX

Grounding: The genset, power supply wiring and

all connected electrical equipment must be bonded
SLOT FOR
to the common grounding system of the boat in ac- REMOTE
cordance with applicable regulations. CONTROL
WIRING
WARNING Faulty grounding of electrical
equipment can lead to fire or electric shock re-
sulting in severe personal injury or death. CONTROL
BOX
Transfer Switch: Use an approved transfer switch
if provision is made for connecting the boat to shore
power. FIGURE 6. TYPICAL AC / CONTROL BOX

17
 REMOTE CONTROL (4 screws). Join the connector and its mate from the
remote control panel.

Remote Control Panels: Various remote control Wiring Remote Control Panel and Connector:
panels and lengths of plug-in wiring harness are Use Figure 7 as a guide for wiring a remote control
available from Onan (Marine Genset Accessories & panel to its connector (mate to the genset connec-
Service Support Catalog). Follow the instructions in tor) when not using a panel available from Onan.
the kits. “Y” harnesses are also available for ap- Check the remote connections against the genset
plications requiring two remote stations. wiring diagram (Page A-1).

Both positions of the Start/Stop switch must be of

Remote Control Connector: The sealed 8-pin the momentary-contact type. Call the factory re-
Deutsch connector for remote connections is garding engine gauge specifications.
stowed inside the genset control box. Remove the
access cover and the rubber plug in the grommet Use 16 AWG wires and sealed 8-pin Deutsch
slot. See the appropriate OUTLINE DRAWING (be- connectors for the wiring harness. Use 14 AWG
ginning Page A-3). Pull the connector out, fit the wires for connector pins 2, 3 and 4 if harness length
grommet into the slot and secure the access cover is 45 to 150 feet (14 to 46 meters).

REMOTE CONTROL PANEL

CONNECTOR

A−A A

8 1
7 2
6 3
5 4

A
STATUS LAMP

RUN LAMP

FIGURE 7. CONNECTIONS BETWEEN REMOTE PANEL AND ITS 8-PIN CONNECTOR

18
 BATTERY WARNING Sparks can ignite fuel leading to se-
vere personal injury or death. Do not run battery
The genset control and cranking circuits are nega- cables and fuel lines together. Separate cables
tive (−) grounded and require a 12 or 24 volt battery. and fuel lines with conduit or tubing if run
A kit is available for isolated DC ground systems. through the same opening. Do not tie together.
To prevent accidental starting of the genset during
Connect the cables from the battery to the genset at
installation, do not connect the battery cables at the
the genset battery terminals mounted on one side of
battery until it is time to start up the genset.
the genset or the other. See the appropriate OUT-
WARNING Accidental or remote starting of the LINE DRAWING (beginning Page A-3). Provide a
genset can can cause severe personal injury or boot over the positive (+) terminal to protect against
death. Do not connect the starting battery until accidental contact. Boots are available from Onan.
it is time to start up the genset.
DC GROUNDING
Batteries: See Specifications for minimum battery
requirements.
The genset must be bonded to the common ground-
Battery Recharging: The genset provides battery ing system of the boat in accordance with applica-
recharging. See Specifications for charging rate. ble regulations. Connect the bonding cable to the
grounding lug beside battery terminals. See the ap-
Battery Location and Mounting: Locate the bat- propriate OUTLINE DRAWING (beginning
tery where spills and leaks will not drip acid on fuel Page A-3).
lines, wiring or other equipment and where ventila-
tion is adequate to prevent the accumulation of ex- WARNING Faulty bonding of the genset to the
plosive gases. Secure the battery so that it cannot common grounding system of the boat can re-
shift and provide a boot over the positive (+) termi- sult in severe personal injury or death.
nal to protect against accidental contact.
FIRE SUPPRESSION SYSTEM
WARNING Arcing can ignite the explosive hy-
drogen gas given off by the battery, causing se-
The genset wiring harness has leads terminating in
vere personal injury. The battery compartment
quick-connects for connection to a fire suppression
must be ventilated and isolated from spark-pro-
system or other control to shut down the genset in
ducing equipment.
the event of fire. See the genset wiring diagram
Battery Cables: Size battery cables according to (Page A-1). The emergency system must close a
Table . Total cable length is the sum of the lengths of set of isolated contacts across J6 and J7 to cause
the positive (+) and negative (−) cables. In other genset shutdown. J7 is Switched B+ and can be
words, total cable length will be approximately twice used to energize devices rated not more than
the distance between the battery and the genset. 0.5 amps.

TABLE . BATTERY CABLE SIZES The connectors are accessible inside the control
TOTAL CABLE LENGTH, CABLE SIZE, box (Page 17). The wiring can exit through the
FEET (METERS) AWG 1/2 inch conduit knockout on the side of the box.
10 (3) 4 Secure the access cover (4 screws) when wiring
14 (4.3) 3 and conduit connections have been made.
18 (5.5) 2
The status indicator light will blink Code
22 (6.7) 1
No. 61—Emergency Shutdown if shutdown oc-
30 (9.1) 1/0 curs. See Troubleshooting (Operator’s Manual).

19
This page is intended to be blank.

20
Frequency and Voltage Adjustments
FREQUENCY ADJUSTMENTS that the engine has the proper levels of oil and
coolant. See the Operator’s Manual. Complete
If it is necessary to change the output frequency for Installation Checks and Startup (Page 23) as
the application, remove the access cover on the left far as possible.
end of the genset (Page A-3). Find the leads
marked J8 HZ, 60 HZ and 50 HZ in the wiring har- 2. Disconnect all generator loads and connect ac-
ness (Page A-1). Connect 60 HZ or 50 HZ to curate meters to measure AC volts and fre-
J8 HZ, as appropriate, and secure the access cover quency.
(4 screws).
WARNING HAZARDOUS VOLTAGE!
VOLTAGE ADJUSTMENTS Touching uninsulated live parts inside the
genset or connected equipment can result
Output voltage may need to be readjusted for the in severe personal injury or death. For your
application, especially if it was necessary to change protection, stand on a dry wooden platform
the frequency and/or reconnect the generator or rubber insulating mat, make sure your
(Page 15). Recheck generator reconnections and clothing and shoes are dry, remove jewelry
reconsider whether frequency needs to be changed from your hands and use tools with insu-
before attempting voltage adjustments. lated handles.
Voltage is adjusted by means of the control switch. 3. Start the genset and let voltage and frequency
Rapidly pressing the switch to START 6 times dur- stabilize for 5 to 10 seconds.
ing the first minute after startup puts the genset con-
troller into voltage set mode. The amber status indi- 4. Rapidly press the control switch to START
cator lamp will begin blinking once every second to 6 times within 10 seconds.
confirm voltage set mode. The green status indica-
5. To adjust voltage up, press the control switch
tor lamp will remain on. The controller resumes nor-
to START and release quickly. Each time the
mal operating mode 20 seconds after the last ad-
switch is released, voltage will rise approxi-
justment.
mately 0.6 volt.
Note: If a fault shutdown occurs or the control switch 6. To adjust voltage down, press the control
is pressed to STOP during voltage set mode, voltage
switch to START and release in approximately
adjustments will not be stored in controller memory.
2 seconds. Each time the switch is released,
To adjust voltage: voltage will drop approximately 0.6 volt.
1. Make sure that proper fuel, exhaust, raw water 7. Normal operation will resume in 20 seconds af-
and battery connections have been made and ter the last adjustment.

21
This page is intended to be blank.

22
Installation Checks and Startup
Before starting the genset, review the installation  If required, the kit for isolated DC ground was
checklist below for those items that do not require installed.
the genset to be actually running. Make necessary
reconnections, modifications and repairs. Then  An approved transfer switch prevents intercon-
start and operate the genset in accordance with the nections with shore power.
Operator’s Manual, observing all of its instructions  AC wiring methods, materials and bonding for
and precautions. Continue working through the grounding meet regulations.
installation checklist with the genset running, mak-
ing necessary reconnections, modifications and re-  A properly sized battery has been installed,
pairs. Check off () each item that can be answered serviced and charged. The battery is securely
positively. Do not place the genset in service until mounted in an adequately ventilated space
each item has been checked off. and the positive (+) terminal is shielded from
accidental contact.
 The RAW WATER PICKUP TEST was con-
 The remote control panel functions as in-
ducted during the sea trials to establish the wa-
tended.
ter line and a siphon break was installed, if
found necessary.  The fire suppression system or other external
 The sea trials established that at all boat emergency system has been tested and shuts
speeds enough raw water is picked up for gen- down the genset as intended.
set engine and exhaust cooling.  The genset is properly sized for the application,
 The sea trials established that there is no back- the voltage and frequency are correct and the
flow through the exhaust through-hull fitting or loads across a multi-phase generator are bal-
water separator drain hose when the boat is anced.
under way, forward or reverse.  Exhaust back pressure is acceptable.
 Genset compartment ventilation meets regula-
tions and the sea trials established that ventila-  The exhaust system is leak-free and conveys
tion is sufficient to maintain acceptable genset all engine exhaust outside, away from win-
compartment temperatures, even while “heat dows, doors and vents.
soaking” after docking.  The fuel supply system is leak-free and air-
 The genset is securely mounted. tight.
 There is adequate clearance for conducting all  The engine coolant and raw water systems are
maintenance specified in the Operator’s Manu- leak-free.
al.
 The engine has the proper levels of oil and
 The coolant recovery tank is mounted properly coolant.
and is accessible for inspection and filling.
 The raw water pump has been primed and the
 The entire exhaust system is accessible for in- sea cock is open.
spection and replacement.
 All operators have been thoroughly briefed on
 Fuel tanks, piping, hoses and filters comply the Operator’s Manual and its safety precau-
with regulations and are accessible for inspec- tions—especially concerning the danger of
tion and replacement. carbon monoxide gas—and can demonstrate
 The genset is bonded to the boat grounding how to operate, maintain and troubleshoot the
system in accordance with regulations. genset as explained therein.

23
This page is intended to be blank.

24
 WIRING DIAGRAM

NOTES:
1. When neither local nor remote gauges are provided, plug re-
sistor R1/R2 assembly into P13 and J9 to P9 and J10 to P10.
2. When local gauges only are provided, plug the gauge assem-
bly into P13 and J9 to P9 and J10 to P10.
3. When local and remote gauges are provided, connect selec-
tor switch S7 as shown. S7, if installed, will be at the local pan-
el. See instruction sheet C605 for further details.
4. When remote gauges only are provided, connect J9 to P11
and J10 to P12.
5. K9 is used for Isolated ground.
6. 24 volt sets have resistor R3 in Fuel Pump (E5) circuit. Gauge
circuits also have resistors (not shown).

612-6757 REVK

A-1
 RECONNECTION DIAGRAMS
612-6757 (2)

A-2
 MDKAV OUTLINE DRAWING (WITH ENCLOSURE)
500-3367(1)

A-3
 MDKAV OUTLINE DRAWING (WITHOUT ENCLOSURE)
500-3367(2)

A-4
 MDKAW & MDKAZ OUTLINE DRAWING (WITH ENCLOSURE)
500-3368(1)

A-5
 MDKAW & MDKAZ OUTLINE DRAWING (WITHOUT ENCLOSURE)
500-3368(2)

A-6
 MDKBD & MDKBE OUTLINE DRAWING (WITH ENCLOSURE)
500-3377(1)

A-7
 MDKBD & MDKBE OUTLINE DRAWING (WITHOUT ENCLOSURE)
500-3377(2)

A-8
 MDKBD & MDKBE OUTLINE DRAWING (WITH PTO)
500-3377(3)

A-9
 MDKBF OUTLINE DRAWING (WITH ENCLOSURE)
500-3378(1)

A-10
 MDKBF OUTLINE DRAWING (WITHOUT ENCLOSURE)
500-3378(2)

A-11
 MDKBF OUTLINE DRAWING (WITH PTO)
500-3378(3)

A-12
 MDKBG OUTLINE DRAWING (WITHOUT ENCLOSURE)
500-3592

A-13
This page is intended to be blank.

A-14
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.
2013 Cummins Power Generation, Inc. All rights reserved.