Installation Manual MDKBJ

Installation Manual
Marine Generator Set
MDKBJ (Spec A)
English - Original Instructions 2-2010 A029Z106 (Issue 2)

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
1. SAFETY PRECAUTIONS ............................................................................................................... 1
1.1 Precaution Symbols ................................................................................................................. 1
1.2 General Precautions ................................................................................................................ 1
1.3 Generator Voltage Is Deadly ................................................................................................... 2
1.4 Engine Exhaust Is Deadly........................................................................................................ 2
1.5 Diesel Fuel is Combustible ...................................................................................................... 3
1.6 Battery Gas is Explosive.......................................................................................................... 3
1.7 Moving Parts Can Cause Severe Personal Injury Or Death ................................................... 3
1.8 Flammable Vapor Can Cause A Diesel Engine To Overspeed............................................... 3
1.9 The Hazards of Carbon Monoxide........................................................................................... 3
1.10 Substance Hazardous to Health ............................................................................................ 5
1.11 Generator Set Warning Labels ............................................................................................ 10
2. INTRODUCTION ........................................................................................................................... 13
2.1 About this Manual .................................................................................................................. 13
2.2 Standards for Safety .............................................................................................................. 13
2.3 Outline Drawings.................................................................................................................... 14
2.4 Noise...................................................................................................................................... 15
2.5 Electromagnetic Compatibility................................................................................................ 15
3. LOCATION AND MOUNTING....................................................................................................... 17

3.1 Lifting The Generator Set ...................................................................................................... 17
3.2 Location ................................................................................................................................. 17
3.3 Mounting The Generator Set ................................................................................................. 18
4. VENTILATION ............................................................................................................................... 19
4.1 Ventilation Exhaust System ................................................................................................... 19
4.2 Carbon Monoxide (CO).......................................................................................................... 19
5. FUEL CONNECTIONS.................................................................................................................. 21
5.1 Fuel ........................................................................................................................................ 21
5.2 Fuel Inlet Fitting ..................................................................................................................... 21
5.3 Fuel Lines and Hoses ............................................................................................................ 21
5.4 Fuel Filters ............................................................................................................................. 22
5.5 Fuel Pickup ............................................................................................................................ 22
5.6 Maximum Fuel Pump Lift ....................................................................................................... 22
A029Z106 (Issue 2) i
Table of Contents 2-2010
5.7 Fuel Anti-Siphon Device ........................................................................................................ 22
6. ENGINE COOLING ....................................................................................................................... 25

6.1 Cooling System Overview...................................................................................................... 25
6.2 System Components.............................................................................................................. 25
7. ENGINE EXHAUST....................................................................................................................... 29
7.1 System Components.............................................................................................................. 29
7.2 Fitting and Hose Diameters ................................................................................................... 29
7.3 Exhaust Hose......................................................................................................................... 29
7.4 Hose Clamps ......................................................................................................................... 29
7.5 Muffler .................................................................................................................................... 29
7.6 Exhaust Water Separator....................................................................................................... 30
7.7 Exhaust Through-Hull Fitting ................................................................................................. 30
7.8 Other Engine Exhaust Systems............................................................................................. 30
7.9 Exhaust Water Separator Backflow Test ............................................................................... 31
8. ELECTRICAL CONNECTIONS..................................................................................................... 35
8.1 Generator............................................................................................................................... 35
8.2 Remote Control...................................................................................................................... 36
8.3 Batteries................................................................................................................................. 38
8.4 DC Grounding ........................................................................................................................ 39
8.5 External Shutdown Devices ................................................................................................... 39
8.6 Optional Network Interface Module (NIM) ............................................................................. 40
9. RECONFIGURING VOLTAGE AND FREQUENCY ..................................................................... 43

9.1 Changing Frequency.............................................................................................................. 43
9.2 Adjusting Voltage ................................................................................................................... 43
10. INSTALLATION REVIEW AND STARTUP.................................................................................. 45
11. SPECIFICATIONS ....................................................................................................................... 47
APPENDIX A. WIRING DIAGRAMS AND OUTLINE DRAWINGS.................................................... 51
ii A029Z106 (Issue 2)
1 Safety Precautions
NOTE: Thoroughly read the Operator manual before operating the generator set.
Safe operation and top performance can only be obtained when equipment is
operated and maintained properly.
NOTE: Only trained and experienced service personnel with knowledge of fuels,
electricity, and machinery hazards shall remove dismantle and dispose of the
generator set. See service manual.
NOTE: Some generator set installation procedures present harzards that can result
in severe personal injury or death. Only trained and experienced personnel
with knowledge of fuels, electricity, and machinery hazards should perform
generator set installation procedures.
1.1 Precaution Symbols

The following symbols in this manual alert you to potential hazards to the operator, service
person and equipment.
DANGER: Used to alert you to a lethal hazard against which you must take steps
to prevent severe personal injury or death, as when you are in the
vicinity of High Voltage equipment.
WARNING: Used to alert you to a hazard or unsafe practice that can result in severe
personal injury or death.
CAUTION: Used to alert you to a hazard or unsafe practice that can result in personal injury or
equipment damage.
1.2 General Precautions

WARNING: Engine components can be hot and cause severe burns, liquid splash and
lacerations of the skin. Use personal protective equipment when working
with or around hazardous materials. Examples of personal protective
equipment include (but are not limited to) safety glasses, protective gloves,
hard hats, steel toed boots and protective clothing.
NOTE: Generator set installation and operation must comply with all applicable
local, state and federal codes and regulations. Only trained and experienced
individuals should install or adjust the generator set.
· Keep children away from the generator set.
· Do not use starting fluids that evaporate. They are highly explosive.
· Do not step on the generator set when entering or leaving the generator room. Parts can
bend or break leading to electrical shorts or to fuel, coolant or exhaust leaks.
· To prevent accidental or remote starting while working on the generator set, disconnect the
negative (-) battery cable at the battery. Hot, moving or electrically live parts can cause
severe personal injury or death.
· Let the engine cool down before removing the coolant pressure cap or opening the coolant
drain. Hot coolant under pressure can spray and cause severe burns.
A029Z106 (Issue 2) 1
1. Safety Precautions 2-2010
· Keep the generator set, drip pan and compartment clean. Oily rags can catch fire. Gear
stowed in the compartment can restrict cooling.
· Make sure all fasteners are secure and properly torqued.
· Do not work on the generator set when mentally or physically fatigued or after having
consumed alcohol or drugs.
· Used engine oil has been identified by some U. S. state and federal agencies as causing
cancer or reproductive toxicity. Do not ingest, inhale, or contact used oil or its vapors.
· Ethylene glycol, used as engine coolant, is toxic to humans and animals. Clean up spills
and dispose of used engine coolant in accordance with local environmental regulations.
· Keep multi-class fire extinguishers handy. Multi-purpose fire extinguishers are used for
fires that involve ordinary combustible materials such as wood and cloth; combustible and
flammable liquid fuels and gaseous fuels; live electrical equipment. (North America or US:
Ref. NFPA No. 10)
· Use personal protective equipment when maintaining or installing the generator set such
as gloves, safety glasses, etc.
1.3 Generator Voltage Is Deadly

Generator electrical output connections must be made by a trained and experienced electrician
in accordance with applicable codes.
WARNING: Interconnecting the generator set and shore power can lead to electrocution
of utility line workers, equipment damage and fire. Use an approved
switching device to prevent interconnections.
CAUTION: Use caution when working on live electrical equipment. Remove all jewelry, make
sure clothing and shoes are dry, stand on a dry wooden platform or rubber
insulating mat and use tools with insulated handles.
1.4 Engine Exhaust Is Deadly

· Properly working carbon monoxide detectors must be located in all living/sleeping areas of
the boat.
· Never sleep in the boat while the generator set is running unless the boat is equipped
with properly working marine carbon monoxide detectors.
· The exhaust system must be installed in accordance with the generator set Installation
manual and be free of leaks.
· Make sure the bilge is adequately ventilated with a power exhauster/blowers.
· Inspect for exhaust leaks every startup and after every eight hours of operation.
· For more information about carbon monoxide see American Boat and Yacht Council
(ABYC) publication TH-22—Educational Information About Carbon Monoxide.
2 A029Z106 (Issue 2)
2-2010 1. Safety Precautions
1.5 Diesel Fuel is Combustible

· Do not smoke or turn electrical switches on or off where fuel fumes are present or in areas
sharing ventilation with fuel tanks or equipment. Keep flames, sparks, pilot lights,
arc-producing equipment and all other sources of ignition well away.
· Fuel lines must be secured, free of leaks and separated or shielded from electrical wiring.
1.6 Battery Gas is Explosive

· Wear splash-proof safety glasses.
· Do not smoke or permit flames or sparks to occur near the battery at any time.
· To reduce arcing when disconnecting or reconnecting battery cables, always disconnect
the negative (-) battery cable first and reconnect it last.
1.7 Moving Parts Can Cause Severe Personal Injury Or

Death
· Do not wear loose clothing or jewelry near moving parts such as PTO shafts, fans, belts
and pulleys.
· Keep hands away from moving parts.
· Keep protective guards in place over fans, belts, pulleys, and other moving parts.
1.8 Flammable Vapor Can Cause A Diesel Engine To

Overspeed
WARNING:
Do not operate a diesel-powered generator set where a flammable vapor environment can
be created by fuel spill, leak, etc.
Flammable vapor can cause a diesel engine to overspeed and become difficult to stop, resulting
in possible fire, explosion, severe personal injury and death. The owners and operators of the
generator set are solely responsible for operating the generator set safely.
1.9 The Hazards of Carbon Monoxide

WARNING: Engine-driven generators can produce harmful levels of carbon monoxide
that can injure or kill you.
1.9.1 What Is Carbon Monoxide Poisoning?

Carbon Monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas. You cannot
see it or smell it. Exposure, even to low levels of CO, for a prolonged period can lead to
asphyxiation (lack of Oxygen) resulting in death.
A029Z106 (Issue 2) 3
Mild effects of CO poisoning include:

· eye irritation
· dizziness
· headaches
· fatigue
· the inability to think clearly
More extreme symptoms include:
· vomiting
· seizures
· collapse
1.9.2 What Are The Special Risks of CO on Boats?

CO may accumulate in the following locations:
· between hulls
· under an overhanging deck
· under a rear swimming platform
· in and around the boat
A swimmer or passengers on deck and in the living quarters can be exposed to lethal levels of
CO when the genset is running, especially when the boat is docked, beached or tied to a
neighboring boat.
The risk of exposure to CO can be multiplied greatly by the "station wagon" effect, obstructions
that block exhaust dissipation and infiltration from neighboring boats. To protect against all three
situations, install reliable and approved marine CO detector alarms on your boat.
WARNING: Carbon Monoxide (CO) gas can cause nausea, fainting or death.
· The Station Wagon Effect: A boat pushes aside the air through which it is moving,
causing a zone of low pressure in the back of the boat and cabins into which exhaust
gases can be drawn (see the Station Wagon Effect - Boat Exhaust figure). A breeze across
an anchored boat can have the same effect. Opening doors and windows so that air can
flow through the boat can reduce the effect.
4 A029Z106 (Issue 2)
FIGURE 1. STATION WAGON EFFECT - BOAT EXHAUST

· Obstructions: Anchoring near a large object such as a boat house or sea wall or in a
confined space such as a canyon can cause exhaust gases to accumulate in and around
the boat despite good generator set maintenance and proper ventilation. Don't run the
generator set when anchored in such places.
· Exhaust from Neighboring Boats: When boats are anchored in close quarters exhaust
from neighboring boats can accumulate in and around yours.
1.9.3 Only You Can Protect Yourself From CO Poisoning!

· Watch constantly for swimmers when the generator set is running.
· Make sure exhaust cannot get under the deck, between hulls or enter the living quarters
through a window, vent or door.
· Make sure all CO detectors are working properly.
· Pay attention to the signs of CO poisoning.
· Check the exhaust system for corrosion, obstruction and leaks each time you start the
generator set and every eight hours if you run it continuously.
1.10 Substance Hazardous to Health

Generator sets use substances, and emit and create wastes that can cause health risks.
Generator set operators must use appropriate personal protective equipment (such as clothing,
gloves, protective glasses/goggles, and respiration equipment) when exposed to fuel, oil,
coolant, wet batteries, grease, cleaning agents, or other substances exposed to lungs, eyes or
skin. Use appropriate containers for transport, storage, and disposal of waste substances.
Follow local regulations for disposal and recycling.
1.10.1 Antifreeze (Fleetguard - ES Compleat/EG Premix)

This antifreeze is also known as an ethylene glycol based coolant; summer coolant; coolant
additive. It is purple colored, viscous liquid, with a mild chemical odor, is soluble in water and
harmful. It contains ethylene glycol, and diethylene glycol. Ethylene glycol is a potentially
hazardous constituent.
The substance has a boiling point of 107° C, and a flash point of 121° C.
It is used as an engine coolant additive, and can be found in engine cooling systems, and heat
exchangers. Installers, operators and maintainers are likely to encounter this substance.
A029Z106 (Issue 2) 5
1.10.2 Hazardous Reactions

Ethylene glycol is combustible when exposed to heat or flame and can react vigorously with
oxidants. Moderate explosive hazard in form of vapor when exposed to heat or flame.
Hazardous products resulting from combustible or decomposition include carbon monoxide,
carbon dioxide and acrid smoke. Self-contained breathing apparatus must be worn in the event
of fume build up.
Avoid strong oxidizing agents - incompatible with sulfuric acid, nitric acid, caustics and aliphatic
amines.
It may cause neurological signs and symptoms, and kidney damage. It is also a skin and eye
irritant.
Very toxic in particulate form upon inhalation. Harmful if swallowed, lethal dose for humans
reported to be 100ml.
1.10.3 Protective Measures

Refrain from eating, drinking or smoking when using the product. Adopt a high standard of
personal hygiene. In case of skin contact, wash immediately with soap and water.
Ensure good ventilation and avoid heat sources. Avoid breathing mist, if there is a risk of vapor,
or particulate, use a suitable organic vapor mask.
Eye protection, gloves, overalls, impervious apron should be used. Avoid contamination inside
the gloves. If overalls become contaminated, discontinue use and clean thoroughly.
1.10.4 Storage/Transport
Store and transport only in correctly marked containers. Keep containers closed when not in
use. Keep cool, out of sunlight and away from naked flames and strong acids, do not freeze.
Store well away from food-stuffs and drinking water. Take special care to avoid discharge into
drains, sewers and water-course.
Contain leak/spill with sand, earth or non-combustible, absorbent material to prevent entry of
substance into drain/sewerage system, water-courses and land. Eliminate all ignition sources,
use plastic shovel to transfer to suitable container and dispose of unwanted or absorbed
substance through an authorized contractor to a licensed site.
1.10.5 Emergency Action

· Fire
Extinguishing media: CO2, alcohol resistant foam, dry powder, or water spray.
Fire fighters to use self contained breathing apparatus. Keep fire exposed containers cool.
Prevent run-off from entering waterways, drains an drinking water supplies.
· Ingestion
Toxic by ingestion. If swallowed induce vomiting only under the advice of a Doctor or
poison control center. Delayed treatment may result in fatality.
· Inhalation (of vapor)
Remove from further exposure. In case of irritation to lungs or throat, seek medical advice.
· Aspiration (inhalation of liquid)
6 A029Z106 (Issue 2)
Obtain immediate medical assistance.

· Eyes
Flush copiously with water or preferably eye-wash solution for at least five minutes. Seek
medical advice.
· Skin
Wash thoroughly with soap and water, and seek medical attention if irritation develops.
Change clothing if necessary and wash before re-use.
· Spillage
Soak-up using an absorbent material and dispose of this as directed under
Storage/Transport.
1.10.6 Gas Oil

This product is also known as Red Diesel, Fuel Oil, and type A1 or A2. It can be pale red or
clear liquid with a characteristic mild odor. It contains catalytically cracked oil, petroleum
distillates, quinizarin, and gas oil maker dye red. The catalytically cracked oil and petroleum
distillates are potentially hazardous constituents.
The substance has an initial boiling point of 180° C, and a flash point greater than 56° C, and a
vapor pressure less than 0.7mm Hg at 20° C and has negligible solubility in water.
It is used as a fuel for off-road diesel powered vehicles and stationary engines, and can be
found in fuel tanks, pipes and injection systems. The substance should not be used for any
other purpose without contacting the manufacturer or supplier. Installers, operators and
maintainers are likely to encounter this substance.

This liquid is flammable. Avoid smoking, heat sources, such as welding and naked flames,
sparks and static electricity build-up. Thermal decomposition products are hazardous, containing
COX, NOX and SOX compounds.
The vapor is explosive. High vapor concentrations can cause respiratory irritation, dizziness,
nausea, and loss of consciousness. Excessive and prolonged exposure to the mist can cause
chronic inflammatory reaction of the lungs and a form of pulmonary fibrosis.
Avoid strong oxidizing agents, e.g. chlorates which may be use in agriculture.
Gas oil is slightly irritating to the skin and has a defatting action. Toxicity following single
exposure to high level of gas oil is of low order. Prolonged, repeated skin contact may de-fat the
skin resulting in possible skin irritation and dermatitis. In some cases warty, cancerous growths
have occurred.

Ensure good ventilation and avoid heat sources. Observance of good housekeeping rules will
ensure general safety. Do not smoke. Avoid breathing mist.
When working on, or testing, injection equipment, special care is required to avoid perforation of
skin by high pressure fuel. Use eye protection in the event of suspected high pressure leak.
Adopt a high standard of personal hygiene. In the case of skin contact, wash well with soap and
water.
A029Z106 (Issue 2) 7
Use glove and overalls, and eye protection goggles if there is a risk of splashing. Use oil
impervious gloves and avoid contamination inside the gloves. If overalls become contaminated,
discontinue use and clean thoroughly. Contaminated clothing should be removed, soaked with
water, and laundered before re-use.
No special respiratory precautions are necessary in normal use.
DO NOT use as a solvent for removing dire/grease etc, from skin.
Store and transport only in correctly marked containers. Keep containers closed when not in
use. Keep cool, out of sunlight and away from naked flames. Electrical continuity is required
between the transport and storage vessels during product transfer.
Contain leak/spill with sand, earth or other suitable material, and prevent entry of substance into
drainage/sewerage system, water-courses and land. Dispose of unwanted or absorbed
substance through an authorized contractor to a licensed site.
Inform local and fire authorities should the product reach waterways, drains etc.
1.10.10 Lubricant Oil - Premium Blue E 15W40

Also known as oil, lube oil, sump oil, new oil is dark, viscous liquid with a slight, characteristic
odor. The base oil contains: distillates (petroleum), solvent-dewaxed heavy paraffinic. It is not
classified as dangerous according to Directive 1999/45/EC and its amendments, and is not
classified according to the EU regulations.
It has a boiling point greater than 150°C, and a flash point Open Cup of 220°C (Cleveland), and
is insoluble in cold water.
It is used in engine lubricant oil systems, sump pan and filters, make-up tanks and piping
systems as a lubrication oil for use in wide range of diesel engines operating under severe
conditions. Installers, operators and maintainers are likely to encounter this product.

This product is stable although slightly re-active with oxidizing agents. Results of decomposition
are carbon oxides (CO, CO2) and water.
Although harmful if swallowed or aspirated (breathed in), repeated or prolonged exposure is not
known to aggravate medical conditions.
Used oil may contain harmful combustion by-products and unburnt fuel that will cause skin
reactions as detailed for fuel. Particular care must be taken if oil form a severely overheated
engine is handled-use impervious gloves, lab coat and safety glasses.
Do no breath vapor/spray.

Ensure good ventilation and avoid heat sources.
Adopt a high standard of personal hygiene. In case of skin contact, wash thoroughly with soap
and water.
Use safety glasses, impervious gloves and lab coat. Avoid contamination inside the gloves. If
overalls become contaminated, discontinue use and clean thoroughly.
8 A029Z106 (Issue 2)
No special respiratory precautions are necessary in normal use. Do not breath vapor/spray
when handling hot materials.
Store and transport only in correctly marked containers. Keep containers tightly sealed when not
in use. Keep cool, well ventilated area, out of sunlight and away from naked flames. Store well
away from food-stuffs and drinking water.
Wear splash goggles, full suit, boots and gloves. Absorb leak/spill with an inert material and
dispose of unwanted or absorbed substance through an authorized contractor to a licensed site.
Finish cleaning by spreading water on the contaminated surface and allow to evacuate through
the sanitary system.

· Fire
Extinguishing media:
Large fire - Use water spray, fog or foam. Do not use water jet.
Small fire - Use dry chemical powder or CO2
Fire-fighters to use self contained breathing apparatus and full turnout gear. Keep fire
exposed containers cool.
· Ingestion
Do not induce vomiting. Obtain medical advice immediately.
Remove from further exposure. Obtain medical attention.
Obtain immediate medical assistance.
· Eyes
Flush copiously with water or preferably eye-wash solution for at least fifteen minutes.
Obtain medical advice.
· Skin
Wash thoroughly with soap and water. Obtain medical advice if irritation develops. Change
clothing if necessary and wash before re-use.
· Spillage
Absorb with an inert material and dispose of this as directed under Storage/Transport.

· Fire
Extinguishing media:
Large fire - Foam/water fog. Never use water jet
Small fire - foam/dry powder, AAAF, CO2, sand, earth.
A029Z106 (Issue 2) 9
Avoid making sparks. Fire fighters to use self-contained breathing apparatus. Keep fire
exposed containers cool, using water fog/spray. Prevent run-off from entering waterway,
drains and drinking water supplies.
· Ingestion
Do not induce vomiting. Wash the mouth out with water, and send to hospital immediately.
Remove from further exposure. Obtain medical assistance immediately.
If, following ingestion of gas oil, vomiting occurs, there is danger of aspiration into the
lungs. This would cause intense local irritation and chemical pneumonities that can be
fatal. Obtain immediate medical assistance.
· Eyes
Irrigate copiously with water or preferably eye-wash solution for at least five minutes. If
irritation persists seek medical advice.
· Skin
Wash thoroughly with soap and water. Change clothing if necessary.
If high pressure injection has occurred prompt surgical attention is required.
· Spillage
Absorb using sand, earth or other suitable material. Dispose of unwanted or absorbed
flammable material as directed under Storage/Transport.
1.10.16 Substance Hazardous to Health

Generator sets use substances, and emit and create wastes that can cause health risks.
Generator set operators must use appropriate personal protective equipment (such as clothing,
gloves, protective glasses/goggles, and respiration equipment) when exposed to fuel, oil,
coolant, wet batteries, grease, cleaning agents, or other substances exposed to lungs, eyes or
skin. Use appropriate containers for transport, storage, and disposal of waste substances.
Follow local regulations for disposal and recycling.
1.11 Generator Set Warning Labels

Warning signs are provided on the generator set at or near the point of risk. To avoid injury,
always take the necessary precautions - as indicated on the sample signs shown below:
Caution/Warning Indicates a risk of personal injury
Caution/Warning of Temperature Hazard.

Indicates a risk of personal injury from high temperature
10 A029Z106 (Issue 2)
Caution/Warning of High Voltage Hazard.

Indicates a risk of personal injury from electric
shock/electrocution.
Caution/Warning of Engine Coolant Pressure Hazard.

Indicates a risk of personal injury from hot pressurized engine coolant.
Caution/Warning.
Indicates to read Operator manual for additional information
Caution/Warning of No Step.
Indicates a risk of personal injury or equipment damage from stepping on
equipment.
Caution/Warning of Combustion/Explosion Hazard.

Indicates a risk of personal injury from explosion.
Caution/Warning of Belt and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.
Caution/Warning of Chemical (ingestion/burn) Hazard.

Indicates a risk of personal injury or asphyxiation from poisonous fumes
or toxic gases.
Caution/Warning of High Voltage or Current Source Hazard.

Indicates a risk of personal injury from electrical shock/electrocution.
A029Z106 (Issue 2) 11
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12 A029Z106 (Issue 2)
2 Introduction
2.1 About this Manual
This manual is a guide for the installation of the generator set(s) listed on the front cover. Proper
installation is essential for top performance. Read through this manual before starting the
installation.
This manual addresses the following aspects of the installation:
· Location and mounting
· Engine exhaust discharge and silencing
· Engine cooling
· Generator set compartment ventilation
· Selection of Ignition Protected devices for areas where gasoline vapors can accumulate
NOTE: This section is only included if your product is marked "ignition protected".
· Preventing the migration of exhaust gases and gasoline vapors into the living quarters.
· Fuel connections
· Electrical connections
· Batteries
· Bonding for grounding
· Accessibility for operation and maintenance
· Noise and vibration
See the generator set Operator manual for operation and Maintenance and the Service manual
for service.
NOTE: Manuals are updated from time to time to reflect changes in the equipment
and its specifications. For this reason, only the copy of the Installation
manual supplied with the generator set should be used as a guide for the
installation.
2.2 Standards for Safety

You must find out which standards for safety are applicable. Compliance with United States
Coast Guard (USCG) regulations is mandatory for boats in U. S. waters. The American Boat
and Yacht Council (ABYC) and the National Fire Protection Association (NFPA) are typical of
agencies that publish safety standards for the construction and installation of marine equipment.
It is suggested that you obtain the following standards:
· USCG regulations are under Titles 33 and 46 of the Code of Federal Regulations (CFR),
U.S. Government Printing Office
Washington, D.C. 20404.
· NFPA No. 302, Pleasure and Commercial Motor Craft,
A029Z106 (Issue 2) 13
2. Introduction 2-2010
National Fire Protection Association

Batterymarch Park
Quincy, MA 02269
· Standards and Recommended Practices For Small Craft,
American Boat and Yacht Council, Inc.
613 Third Street, Suite 10
Annapolis, MD 21403
Particular attention should be paid to ABYC P-1, Installation of Exhaust Systems for Propulsion
and Auxiliary Machinery, ABYC E-11, AC and DC Electrical Systems on Boats and ABYC A-27,
Alternating Current (AC) Generator Sets.
WARNING: This generator set is not a life support system. It can stop without warning.
Children, persons with physical or mental limitations, and pets could suffer
personal injury or death. A personal attendant, redundant power or an alarm
system must be used if generator set operation is critical.
WARNING: This generator set is not "ignition protected" and shall not be used in
flammable vapor environment.
WARNING: This generator set shall not be the main source of power for communication
and steering systems. It can stop without warning.
2.3 Outline Drawings

See the applicable outline drawing for installation details, such as:
· mounting bolt hole locations
· connection points
· fuel
· battery
· raw water
· exhaust
· remote control
· AC output
· sizes and types of fittings
· overall dimensions
See your Cummins distributor for large-scale copies of the applicable drawings.
WARNING: Improper installation can result in severe personal injury, death and
equipment damage. The installer must be qualified to perform installation of
electrical and mechanical equipment.
14 A029Z106 (Issue 2)
2-2010 2. Introduction
2.4 Noise
Generator sets emit noise. As noise level and time of exposure increase, risk of hearing
damage increases. The Specifications page in the operator manual states noise level for this
generator set. Select and use personal hearing protection appropriate for your exposure to
generator set noise.
Note for use in countries where compliance to the EU Noise directive is required: This generator
set has not been evaluated and is not marked for use in open air. Install the generator set in
accordance with the installation manual. Obey local noise restrictions when you operate the
generator set.
2.5 Electromagnetic Compatibility

Generator sets emit noise and receive electromagnetic (radio frequency) energy. If the
generator set affects operation of nearby devices, or nearby devices affect generator set
operation, increase the distance between them.
Note for use in countries where compliance to the EMC directive is required: This generator set
has been evaluated for use in residential, commercial, and light industrial environments.
A029Z106 (Issue 2) 15
2. Introduction 2-2010
16 A029Z106 (Issue 2)
3 Location and Mounting
WARNING: Installation of the generator set requires lifting apparatus. Ensure that
correctly rated lifting slings with suitable attachments are available prior to
commencing work. Lifting and lowering operations should only be carried
out by properly trained personnel. Do not exceed the rating of any lifting
component. Wear head, eye, hand and foot protection during lifting
operations.
3.1 Lifting The Generator Set

The genset has two lifting eyes which are accessible by removing the top access covers.
· Use both lifting eyes.
· Use proper equipment for safe handling.
Save the four steel clamps that secured the genset to the shipping skid if they are to be used for
securing the genset to the floor or frame.
See the Mounting The Generator Set section of this manual.
3.2 Location
Additional considerations (sections of this manual) that bear on location include:
· Ventilation
· Fuel Connections
· Engine Cooling
· Engine Exhaust
NOTE: Because of noise, vibration and fumes, the generator compartment should be
located as far from living quarters as practical.
Locate the generator set where it will be protected from weather and splashing or dripping
water.
NOTE: The housing on some models is for reducing noise, not for protection
against weather or water.
Locate the generator set where there will be enough room to perform periodic maintenance and
service.
· Non-service sides should have at least 2 inches (51 mm) of clearance.
· The left side and right side discharge duct should have at least 1 inch (25 mm) of
clearance for air flow.
· The front must have at least 2 inches (51 mm) of clearance to unlatch the access door.
· The right side must have enough clearance to remove the side panel for adjusting the
V-belt, replacing the pump impeller and servicing the heat exchanger.
Make sure there is access for:
· Starting and stopping the generator set
A029Z106 (Issue 2) 17
3. Location and Mounting 2-2010
· Resetting the line circuit breakers

· Checking, filling and draining engine oil
· Changing the engine oil filter
· Checking, filling and draining engine coolant
· Replacing coolant and exhaust hoses
· Replacing the raw water pump impeller
· Replacing the V-belt
· Changing the fuel filter
· Making fuel connections
· Making battery and ground connections
· Making AC connections
· Making remote control connections
· Inspecting the drive belt system and generator bearing at the back of the generator set
3.3 Mounting The Generator Set

The generator set has integral vibration isolators. The supporting structure underneath should
be level and able to support the weight of the generator set. The floor must extend under the
whole base pan for support. Floor or frame stiffness should be greatest under the vibration
isolators.
Secure the generator set to the floor in one of the following ways:
· Bolt it with three (3) bolts through the bolt holes in the drip pan.
· Clamp it with the four (4) steel clamps that secured it to the shipping skid; one at each
corner. A clamp can be on either side of a corner.
· Bolt it through the front bolt hole in the drip pan and clamp each rear corner with a steel
clamp.
NOTE: To reduce noise, plug the unused clamp openings in the drip pan with the
four rubber plugs shipped in the literature packet.
18 A029Z106 (Issue 2)
4 Ventilation
WARNING: EXHAUST GAS IS DEADLY! FUEL VAPORS ARE EXPLOSIVE! Failure to
provide proper ventilation can result in asphyxiation, fire and expolsion. The
ventilation system must meet applicable standards and regulations, including
USCG, NFPA and ABYC. See the Standards For Safety section of this
manual.
4.1 Ventilation Exhaust System

Ventilation is required to prevent dangerous concentrations of fuel vapors and exhaust fumes,
hold down compartment temperatures and provide combustion air.
To promote convection, and ensure proper engine cooling:
· Ventilating air should enter at the bottom of the compartment (near the air inlet) and exit at
the top (near the air outlet).
· The free-air area of the inlet air coil should be at least twice that of the duct.
· Use 40 in2 (258 cm2) as the basis for calculations for inlet and outlet air duct sizes
and free-air areas of screens and louvers.
NOTE: When calculating air flow required for combustion and ventilation, refer to
the Specifications section of this manual for data regarding air flow and heat
radiated to the room.
· Do not use flush air inlets or louvered transom outlets, which are easily blocked.
· Make sure that the flow of cooling and ventilating air does not recirculate back into the
generator set causing further heating of the generator set.
· Measure cooling air temperature at the generator set air inlet.
· Inlet air temperature should not exceed 122° F (50° C) when the generator set is
running under full load.
· The inlet air temperature at the generator set may exceed 122° F (50° C) briefly after
the main engines have been shut down.
4.2 Carbon Monoxide (CO)

All openings and feed-through holes for wiring, conduit, pipe and hose must be sealed to
prevent exhaust gases from entering the rest of the boat. Wiring conduit must be sealed inside
as well as outside.
Cabin plumbing drains must have approved traps to prevent the entrance of exhaust gases from
outside.
4.2.1 CO Detector-Alarms
Carbon monoxide (CO) detector-alarms, listed for marine applications, must be installed in the
living quarters of the boat. Wind shifts, boat motion, exhaust from other boats at dockside and
other conditions can cause exposure to harmful concentrations of carbon monoxide even when
proper ventilation is provided and living quarters are sealed off from engine rooms.
A029Z106 (Issue 2) 19
4. Ventilation 2-2010
20 A029Z106 (Issue 2)
5 Fuel Connections
KEEP THIS MANUAL NEAR THE GENERATOR SET FOR EASY REFERENCE.
5.1 Fuel
WARNING: Diesel fuel is combustible and can cause severe personal injury or death. Do
not smoke near fuel tanks or fuel-burning equipment or in areas sharing
ventilation with such equipment. Keep flames, sparks, pilot flames, electrical
arcs and switches and all other sources of ignition well away. Keep a
multi-class ABC fire extinguisher handy.
CAUTION: Do not use galvanized fuel tanks or piping. The trace of sulfur in diesel fuel attacks
galvanized (zinc) coatings causing debris that can clog fuel filters, pumps and
injectors.
High quality Grade 2-D diesel fuel is necessary for good performance and long engine life.
Diesel fuels specified by EN 590 or ASTM D975 are recommended.
NOTE: Use Grade 1-D diesel fuel if the fuel tank is exposed to temperatures below
40° F (5° C).
· The Cetane number should not be less than 45 and sulfur content not more than 0.5% (by
weight).
· Where fuel is exposed to cold ambient temperatures, use fuel that has a cloud point
(temperature at which wax crystals begin to form) at least 10° F (6° C) below the lowest
expected fuel temperature.
· Fuel lubricity should pass a minimum load level of 3100 grams as measured by ASTM
D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO
12156-1.
NOTE: Ultra Low Sulfur Diesel (ULSD) fuel that meets the ASTM D975 standard for
lubricity is suitable for use with this engine. The 1-2% less energy content of
the fuel can have a slight effect on maximum engine power.
NOTE: B5 Bio-Diesel fuel that meets industry specifications and quality is suitable
for use with this engine.
5.2 Fuel Inlet Fitting

A 1/8 NPT fuel inlet fitting is mounted on the drip pan on the right side.
5.3 Fuel Lines and Hoses

Use USCG Type A1 or ISO 7840-A1 fuel hoses.
· An inside diameter of 5/16 inch (8 mm) is recommended for fuel lines and hoses.
· An inside diameter of 1/4 inch (7 mm) should be considered in applications where fuel lines
are short and lift minimal.
A029Z106 (Issue 2) 21
5. Fuel Connections 2-2010
NOTE: Larger diameter fuel lines are harder to prime and keep primed and are thus
more likely to cause disruption of generator set service.
Run the fuel lines as directly as possible, avoiding dips and crests that trap air and cause hard
priming.
NOTE: Fuel hoses connected at the generator set must be non-conductive so that
the fuel lines do not become paths for cranking current. Because the fuel
tanks are required to be bonded to the common negative [-] grounding
system of the boat, conductive fuel lines connected directly to the generator
set will carry cranking currents.
WARNING: Fire can result when fuel lines carry cranking current. Use non-conductive
fuel hoses for connections at the generator set to prevent the fuel lines from
becoming paths for cranking current.
5.4 Fuel Filters

The generator set is equipped with a water-separator fuel filter. It is recommended that a 10 to
30 micron water-separator fuel filter be installed in the fuel supply system to protect the fuel lift
pump.
5.5 Fuel Pickup

Provide a separate pickup tube in the fuel tank for the genset.
· The inside diameter should be 1/4 inch (6.35 mm).
· The inside diameter must not be greater than 3/8 inch (9 mm).
NOTE: In a common fuel supply tank, the genset pickup tube should be shorter than
those for the propulsion engines so that the genset cannot empty the fuel
tank.
5.6 Maximum Fuel Pump Lift

· The genset fuel inlet fitting must not be more than 48 inches (122 cm) higher than the
bottom of the fuel pickup tube.
· The suction required at the genset fuel inlet to overcome lift and line flow resistance
(including fittings, filters and valves) must not exceed 3 inches Hg (10 kPa).
5.7 Fuel Anti-Siphon Device

If any part of the fuel line is routed below the top of the fuel tank, a fuel anti-siphon device must
be installed at the tank fitting to prevent accidental discharge of fuel.
5.7.1 Check Valve-Type Anti-Siphon Devices

A fuel check valve used as an anti-siphon device requires a pull-off vacuum of less than 1.6
inches Hg (5.5 kPa or 0.8 psi).
22 A029Z106 (Issue 2)
2-2010 5. Fuel Connections
5.7.2 Solenoid-Type Anti-Siphon Devices

The genset wiring harness has leads with quick-connect terminals labeled SWB+ and
CUSTOMER GND (B-) that can be connected to power a pilot relay for a fuel solenoid stop
valve at the fuel tank fitting. They are accessible by removing the access cover on the left end
of the genset. The total load on SWB+ must not exceed 0.5 amps.
NOTE: The genset leaves the factory with SWB+ jumpered to two other connectors,
ESTOP and CO. When making connections for a fuel solenoid pilot relay,
SWB+ must continue to be jumpered to ESTOP and CO unless they are
connected to normally closed external shutdown devices, otherwise the
genset will not run.
A029Z106 (Issue 2) 23
5. Fuel Connections 2-2010
24 A029Z106 (Issue 2)
6 Engine Cooling
6.1 Cooling System Overview
The engine is cooled by a pressurized, closed-loop liquid cooling system in which coolant is
pumped through passages in the engine block, head and exhaust manifold. The exhaust
manifold also serves as the engine coolant reservoir.
The heat exchanger is mounted inside the exhaust manifold. Raw water (the flotation water) is
pumped through tubes in the heat exchanger to cool the engine coolant and then is passed
through a hose into the exhaust-water mixer to cool the exhaust gases. The raw water is
expelled from the boat along with the exhaust gases. The V-belt drives the coolant and the raw
water pumps.
6.2 System Components

6.2.1 Raw Water Pump
The raw water pump:
· Can work against a maximum lift (suction) of 48 inches (122 cm) WC to deliver the
required flow of cooling water.
· The pump impeller must be wetted with water to establish initial pump lubrication and
suction.
NOTE: "Lift" is a combination of the actual vertical lift and the resistance to flow
caused by the hose, strainer, sea cock and through-hull fitting.
6.2.2 Raw Water Hose

The 3/4 inch (19.1 mm) hose barb for raw water pickup is mounted on the drip pan on the right
side.
· Use SAE 20R3 or equivalent hose to supply raw water to the genset.
· The hose must be able to resist a slight vacuum.
6.2.3 Raw Water Strainer

Locate the raw water strainer below the raw water pump and as close to it as practical.
· The basket must be removable for cleaning.
· Fill the raw water strainer for faster priming at startup if it is above the water line.
6.2.4 Sea Cock

Install a bronze, full-flow sea cock on the through-hull fitting.
A029Z106 (Issue 2) 25
6. Engine Cooling 2-2010
6.2.5 Through-Hull Fitting and Strainer

Locate the through-hull fitting as close to the genset as possible.
· If the strainer has slotted openings, the slots must be parallel to the keel for best flow when
the boat is under way
· Stagger the through-hull fittings along the keel so that downstream fittings are not starved.
CAUTION: Do not use a scoop-type through-hull fitting. A forward-facing scoop can develop
enough ram pressure to flood the engine. A rear-facing scoop can develop enough
suction to impede flow.
6.2.6 Siphon Break

Conduct the Raw Water Pickup Test to determine whether a siphon break is required to
prevent the engine from being flooded with floatation water.
· Siphon break kit 541-0876-01 is available if a siphon break is required. Carefully follow
the instructions in the kit.
· The hoses in the kit replace the hose between the engine heat exchanger and
exhaust-water mixer.
CAUTION: Engine damage due to flooding as a result of failing to install a required siphon
break is not covered by warranty.
6.2.7 Coolant Recovery Tank

The genset is shipped with a coolant recovery tank kit. Follow the instructions in the kit.
· The tank must be accessible for daily inspection and refilling.
· Clamp the recovery hose to the hose barb on the coolant fill neck.
· Route the tank recovery and overflow hoses through the holes in the end of the enclosure.
· Make sure the overflow hose terminates in the drip pan where it will not splash coolant on
electrical components.
· Fill the tank in accordance with the Operator manual.
6.2.8 Initial Coolant Fill

The generator set is normally shipped from the factory with coolant, unless prohibited by
shipping regulations. Fill the system, if necessary, in accordance with the Operator manual.
CAUTION: Running the engine without coolant can cause damage not covered by Warranty.
6.2.9 Raw Water Pickup Test

6.2.9.1 Objective
The objective is to determine the elevation of the water line relative to the generator set under
all anticipated uses and speeds of the boat.
26 A029Z106 (Issue 2)
2-2010 6. Engine Cooling
6.2.9.2 Method
When the boat is ready for its sea trials and loaded to its maximum rated capacity:
1. Close the sea cock and disconnect the raw water pickup hose from the generator set.
NOTE: Alternatively, connect a clear plastic hose to the strainer or sea cock.
2. Raise the end of the hose above expected water level and open the sea cock. While the
boat is still docked, mark the level on the generator set enclosure.
NOTE: The water line is at the level visible in a clear plastic hose or where water just
begins to spill as the end of the hose is lowered.
3. Operate the boat through its speed range, forward and reverse. While the boat is
operating, have someone monitor the water level in the hose and mark the highest level on
the generator set.
6.2.9.3 Requirement
A siphon break must be installed if the engine exhaust-water mixer is not at least 6 inches (152
mm) above both water lines (docked and moving).
NOTE: If the water line is much higher while the boat is moving, as opposed to while
the boat is docked, the difference could be due to the through-hull fitting or
its location. If the through-hull fitting is of the forward-facing scoop-type
designed to create ram pressure, replace it with a flush-type fitting. Another
possibility might be to move the fitting to a location where the dynamic hull
pressure is less.
A029Z106 (Issue 2) 27
6. Engine Cooling 2-2010
28 A029Z106 (Issue 2)
7 Engine Exhaust
7.1 System Components
WARNING: EXHAUST IS DEADLY! The exhaust system must be leak-free and convey all
exhaust outside the boat, away from windows, doors and vents.
See the Engine Cooling chapter of this manual for information on raw water connections.
The installation MUST comply with applicable standards and regulations, including those of the
USCG and ABYC.
Mufflers, water separators, resonators and siphon breaks are available as kits from Cummins
Onan. Muffler kits include a strainer for the through-hull fitting.
7.2 Fitting and Hose Diameters

NOTE: No fitting or hose section in the exhaust system may have a smaller inside
diameter than the genset exhaust outlet.
Exhaust back pressure must be measured if the total run of the exhaust system is more than 20
feet (6 meters). Use larger diameter hose if back pressure exceeds 3 inches Hg (10 kPa).
7.3 Exhaust Hose

Use a hose that has been approved for wet exhaust systems.
· Horizontal runs of the hose must slope down at least 1/2 an in/ft (42 mm/meter) and be
supported such that there are no sags.
· Approved hoses and stainless steel elbows are available from Cummins Onan.
NOTE: The entire run of hose must be accessible for regular, visual inspections and
replacement.
7.4 Hose Clamps

Use two stainless steel hose clamps at least 1/2 inch (12.7 mm) wide to clamp each end of
each hose.
7.5 Muffler
Install the muffler as close as practical to the engine.
When installing the muffler, be sure to observe the following requirements:
· The length of hose between the genset and the muffler should be 1 to 5.5 ft (30 to 170
cm).
· The muffler inlet must be more than 1 ft (30 cm) below the exhaust-water mixer.
A029Z106 (Issue 2) 29
7. Engine Exhaust 2-2010
· The muffler outlet hose must rise straight up from the muffler into a water separator or
elbow that turns sharply down.
· When a water separator is in use, the base of the muffler should not be more than 54 in
(1.4 m) below the top of the water separator.
· When an elbow is used, the base of the muffler should not be more than 48 in (1.2 m)
below the elbow.
· The muffler must be mounted such that air can circulate underneath to prevent
condensation and mold.
7.6 Exhaust Water Separator

When an exhaust water separator is used, the muffler outlet and water separator inlet diameters
must be the same size.
· The water separator should be installed directly above the muffler to maintain a vertical lift.
· The through-hull fitting for the drain hose should be below the load water line and must
have a sea cock.
NOTE: An Exhaust Water Separator Backflow Test must be conducted during the
sea trials to determine that there is no backflow that could flood the engine.
7.7 Exhaust Through-Hull Fitting

The exhaust through-hull fitting must be above the load water line under all anticipated uses and
speeds of the boat.
· To reduce wave wash-in when a water separator is used, the top of the water separator
must be at least 18 inches (450 mm) above the load water line.
· When an elbow is used at the top of the muffler outlet hose, the elbow must be at least 12
inches (305 mm) above the through-hull fitting.
CAUTION: Backflow can cause major engine damage if the cylinders become flooded. The
sea trials must verify that there is no backflow through either the exhaust hull fitting
or the water separator drain hose fitting.
7.8 Other Engine Exhaust Systems

NOTE: Do not "T" into any other engine exhaust system.
Run the genset exhaust piping all the way to the hull and terminate it flush with or extended
slightly from the outside of the hull.
CAUTION: Corrosive exhaust vapors can migrate through a shared exhaust system and cause
damage to idle engines. Provide a separate exhaust system for each engine.
30 A029Z106 (Issue 2)
2-2010 7. Engine Exhaust
7.9 Exhaust Water Separator Backflow Test

7.9.1 Objective
To determine that there is no backflow through the exhaust water separator under any operating
condition.
7.9.2 Method
Conduct this test during the sea trials in conjunction with the Raw Water Pickup Test.
· Prepare by closing the drain hose sea cock and disconnecting the hose from the water
separator.
· Conduct the test by opening the sea cock while keeping the hose raised to its fitting on the
water separator.
7.9.3 Requirement
There must not be any backflow while operating the boat throughout its speed range.
· If there is backflow while operating the boat, relocate the through-hull fitting.
FIGURE 2. TYPICAL INSTALLATION ABOVE LOAD WATERLINE - WITH A MUFFLER AND WATER
SEPARATOR
A029Z106 (Issue 2) 31
FIGURE 3. TYPICAL INSTALLATION ABOVE LOAD WATERLINE - WITH A MUFFLER AND

RESONATOR
32 A029Z106 (Issue 2)
2-2010 7. Engine Exhaust
FIGURE 4. TYPICAL INSTALLATION BELOW LOAD WATERLINE - WITH A SIPHON BREAK,

MUFFLER AND WATER SEPARATOR
A029Z106 (Issue 2) 33
FIGURE 5. TYPICAL INSTALLATION BELOW LOAD WATERLINE - WITH A SIPHON BREAK,

MUFFLER AND RESONATOR
34 A029Z106 (Issue 2)
8 Electrical Connections
WARNING: Accidental or remote starting can cause severe personal injury or death. To
prevent accidental starting, disconnect the negative (-) battery cable from the
battery before working on the genset.
WARNING: HAZARDOUS VOLTAGE! Touching uninsulated live parts inside the genset
and connected equipment can result in severe personal injury or death. For
your protection, stand on a dry wooden platform or rubber insulating mat,
make sure your clothing and shoes are dry, remove jewelry from your hands
and use tools with insulated handles.
WARNING: Improper wiring can cause fire or electric shock resulting in severe personal
injury or death.
8.1 Generator
8.1.1 Wiring Methods
All wiring methods, connections, wire current capacity, equipment grounding and materials must
be inspected and comply with applicable regulations. Use flexible conduit and stranded
conductors for load wiring to take up movement and vibration.
NOTE: All feed-through holes in decks and bulkheads for wiring must be sealed to
prevent exhaust gases and flammable vapors from entering the rest of the
boat. Wiring conduit must be sealed inside as well as outside
8.1.2 Generator Connections/Reconnections

Make generator connections and reconnections as required (see the Wiring Diagrams and
Outline Drawings).
NOTE: When reconnecting the generator for a different output voltage, make sure
the line circuit breakers are suitable for the new output. Replace them if
necessary with ones of appropriate rating.
NOTE: See the Reconfiguring Voltage and Frequency chapter of this manual if it is
necessary to change frequency or to readjust voltage.
8.1.3 Grounding
The generator set, power supply wiring and all connected electrical equipment must be bonded
to the common grounding system of the boat in accordance with applicable regulations.
WARNING: Faulty grounding of electrical equipment can lead to fire or electric shock
resulting in severe personal injury or death.
8.1.4 Transfer Switch

When the boat has provisions for connection to shore power, the genset must be connected to
the boat electrical system through an approved transfer switch to prevent backfeed.
A029Z106 (Issue 2) 35
8. Electrical Connections 2-2010
WARNING: Backfeed to shore power can lead to electric shock resulting in severe
personal injury or death. Prevent backfeed by connecting the genset to the
boat electrical system through an approved transfer switch.
8.1.5 Load Balancing

Loads should be balanced as closely as possible across the generator phases.
8.2 Remote Control

8.2.1 Remote Control Connector
The sealed 8-pin Deutsch® connector for remote connections is stowed inside the genset.
Remove the access cover on the left end of the enclosure.
Remove and discard the solid rubber slot plug (not the one with the round plastic insert). See
the Outline Drawing.
Pull the connector out, fit the wire grommet into the slot and secure the access cover. Remove
the protective cap over the connector pins and join the connector and it's mate from the
Cummins Onan Digital Display and/or remote switch and meters.
8.2.2 Cummins Onan Digital Display

Up to three (3) Cummins Onan Digital Displays may be connected for remote control and
monitoring of the genset.
The Cummins Onan Digital Display is not ignition protected and must therefore be installed in
spaces isolated from gasoline fuel sources. Follow the installation instructions in the Display kit.
8.2.3 Remote Control Switch and Meter

8.2.3.1 Cummins Onan Remote Control Panel Kit
Remote control panels with a control switch or a control switch with a DC voltmeter or hour
meter are available as kits.
Follow the installation instructions in the kit.
NOTE: These panels are not ignition protected and must therefore be installed in
spaces isolated from gasoline fuel sources.
8.2.3.2 Non-Cummins Onan (Customer Supplied) Remote Control Panel

Use the Connections Between Remote Panel and Its 8-Pin Connector figure as a guide for
wiring a remote switch and meters to mate with the genset remote connector.
Start-Stop switches must be momentarily contacted in both positions.
NOTE: The panel must be installed in spaces isolated from gasoline fuel sources
unless all of its components are ignition protected devices.
36 A029Z106 (Issue 2)
2-2010 8. Electrical Connections
FIGURE 6. CONNECTIONS BETWEEN REMOTE PANEL AND ITS 8-PIN CONNECTOR
8.2.4 Remote Control Wiring Harnesses

8.2.4.1 Cummins Onan Harness
Eight-conductor plug-in wiring harnesses of various length are available for connecting the
Cummins Onan Digital Displays and/or a remote switch and meters.
8.2.4.2 Non-Cummins Onan (Customer Supplied) Harnesses

· Use 16 AWG wiring. For harnesses 45 to 150 feet (14 to 46 meters) long, use 14 AWG
wiring at connector pins 2, 3 and 4.
· Harnesses for Cummins Onan Digital Displays must have eight (8) connectors.
· Harnesses for remote switches and meters only must have at least six (6) conductors
(connector pins 7 and 8 are not used).
NOTE: All feed-through holes in decks and bulkheads for wiring must be sealed to
prevent exhaust gases and flammable vapors from entering the rest of the
boat. Wiring conduit must be sealed inside as well as outside.
NOTE: Do not route remote control wiring near AC wiring. AC can induce false
signals that can cause erratic operation of the generator set.
8.2.5 Warning Labels

Each Cummins Onan kit for an Cummins Onan Digital Display or remote control panel includes
the following warning statement:
A029Z106 (Issue 2) 37
WARNING: Gasoline vapors can explode. Before starting the genset, operate the exhaust
blower for 4 minutes and check the genset compartment and bilge for
gasoline vapors.
This label or equivalent must be affixed next to each Cummins Onan Digital Display or genset
start switch and be visible when starting the genset at that station.
8.3 Batteries
CAUTION: Wear splash-proof safety glasses.
The genset control and cranking circuits are negative (-) grounded and require a 12 volt battery.
A kit is available for isolated DC ground systems.
To prevent accidental starting of the genset during installation, do not connect the battery cables
at the battery until it is time to start up the genset.
WARNING: Accidental or remote starting of the genset can cause severe personal injury
or death. Do not connect the starting battery until it is time to start up the
genset.
See the Specifications section for minimum battery requirements and the optional battery
charger battery charging rate.
8.3.1 Disabling the Optional Battery Charger

If it is necessary to disable battery charging for the application, disconnect the leads marked B1,
B2 and B+ from the quick-connect terminals on battery charging voltage regulator A1 (see the
appropriate Wiring Diagram).
The regulator is mounted below and to the left of the ignition coil. Insulate the end of each lead
with several wraps of listed electrical insulating tape and tie them neatly in the wiring harness.
8.3.2 Battery Location and Mounting

Locate the battery where spills and leaks will not drip acid on fuel lines, wiring or other
equipment and where ventilation is adequate to prevent the accumulation of explosive gas.
WARNING: Arcing can ignite the explosive hydrogen gas given off by the battery,
causing severe personal injury. The battery compartment must be ventilated
and isolated from spark-producing equipment.
8.3.3 Battery Cables

Size the battery cables according to the Battery Cable Gauges table below. Provide an
insulating boot over the positive (+) terminal to protect against accidental contact.
Total cable length is the sum of the lengths of the positive (+) and negative (-) cables, total
cable length will be approximately twice the distance between the battery and the generator set.
See the appropriate outline drawing regarding the battery cable terminal locations.
WARNING: Sparks can ignite fuel leading to severe personal injury or death. Do not run
battery cables and fuel lines together. Separate cables and fuel lines with
conduit or tubing if run through the same opening. Do not tie together.
38 A029Z106 (Issue 2)
TABLE 1. BATTERY CABLE GAUGES
Total Cable Length, Feet (Meters) Cable Gauge

AWG Approximate Diameter (mm)*
10 (3) 4 5.88
14 (4.3) 3 6.61
18 (5.5) 2 7.42
22 (6.7) 1 9.43
30 (9.1) 1/0 9.46
* Minimum diameter when using metric gauge cables.
8.3.4 Genset Battery Terminals

Connect the cables from the battery to the genset at the genset battery terminals mounted on
the drip pan.
8.3.5 B+ Terminal Insulating Boots

Provide insulating boots over the B+ battery cable terminals at the battery and at the genset to
protect them from contact with metal objects that could short to ground.
8.4 DC Grounding
8.4.1 Common Ground
The genset must be electrically bonded to the common grounding system of the boat in
accordance with applicable regulations.
Connect the bonding cable to the genset bonding lug mounted on the drip pan.
WARNING: Faulty bonding of the genset to the common grounding system of the boat
can lead to fire or explosion, resulting in severe personal injury or death.
8.5 External Shutdown Devices

8.5.1 External Shutdown Devices
The genset will stop running if the circuit is opened between SWB+ and either of the other two
connectors, ESTOP or CO. Therefore use normally-closed (NC) shutdown devices.
NOTE: The total load on SWB+ must not exceed 0.5 amps.
8.5.2 Factory Jumpers

The genset leaves the factory with SWB+ jumpered to the other two connectors, ESTOP and
CO.
CAUTION: Leave the jumpers connected when no external shutdown devices are to be
connected, otherwise the genset will not run.
A029Z106 (Issue 2) 39
8.5.3 Wiring Grommet and Strain Relief

· Remove and discard the round plastic plug in the rubber grommet next to the access
cover.
· Push the external wires and conduit through the grommet before making connections.
· Use wire ties to provide strain relief for the external leads.
· Secure the access cover when connections have been made.
8.5.4 Shutdown Indication

If shutdown occurs due to either device, the Cummins Onan Digital Displays will display,
respectively, Code No. 5: Warning - Shutdown due to Vessel CO or Code No. 61:
Emergency Shutdown.
See the Troubleshooting chapter of the Operator manual for more information.
NOTE: All of the status indicator lights in the control circuit will also blink the fault
code.
8.6 Optional Network Interface Module (NIM)

The optional NIM board is mounted in a box on the side of the generator set. It has an open
12-pin connector socket for external network connections that mates with a Deutsch® part
number DT06-12S sealed 12-pin connector plug.
NOTE: For SAE 1939 applications see your Onan distributor for more information.
Onan publication D-3315, Supported Messages on SAE J1939, must be used
in designing the interface for monitoring generator set status and
diagnostics.
NOTE: For SmartCraftTM applications see your Cummins MerCruiser Distributor for
more information.
The NIM board has five (5) jumpers to configure the board for the specific application.
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
application. The jumper must remain uncut when the generator set is ordered for a
SmartCraftTM network 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
jumpers as scheduled.
TABLE 2. J1939 ADDRESSES
Jumper W3 Jumper W4 Address

Not Cut Not Cut 234
Not Cut Cut 158
Cut Not Cut 179
Cut Cut 203
40 A029Z106 (Issue 2)
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 SmartCraftTM board.)
FIGURE 7. NETWORK INTERFACE MODULE CONFIGURATION JUMPERS
A029Z106 (Issue 2) 41
42 A029Z106 (Issue 2)
9 Reconfiguring Voltage and Frequency
9.1 Changing Frequency
Model MDKBJ gensets may be configured to operate at 60 Hz or 50 Hz.
To change the operating frequency:
1. Remove the front access door and find wiring harness connectors P5, P6 and P7.
2. Connect P5 to P6 for 60 Hz.
3. Connect P5 to P7 for 50 Hz.
NOTE: When changing genset operating frequency, make sure the line circuit
breakers are suitable for the new output. Replace them if necessary with
ones of appropriate rating.
NOTE: Check and adjust voltage as necessary after the frequency has been
changed.
9.2 Adjusting Voltage

WARNING: HAZARDOUS VOLTAGE! Touching uninsulated live parts inside the genset or
connected equipment can result in severe personal injury or death. For your
protection, stand on a dry wooden platform or rubber insulating mat, make
sure your clothing and shoes are dry, remove jewelry from your hands and
use tools with insulated handles.
Before adjusting voltage, make sure that proper fuel, exhaust, raw water and battery
connections have been made and that the engine has the proper levels of oil and coolant.
Disconnect all generator loads and connect accurate meters to measure AC voltage and
frequency.
9.2.1 Using the Start Switch

1. Start the genset and let voltage and frequency stabilize for 5 to 10 seconds.
2. Rapidly press START 6 times during the first minute after startup, to put the generator
controller into voltage adjust mode.
1. The amber status light will begin blinking about once every second to indicate the
change to voltage adjustment mode.
2. The green status light will remain on.
3. To adjust voltage UP:
a. Press and quickly release START.
a. Voltage will increase approximately 0.6 volts each press and release.
b. Continue to press and release (quickly) START until the voltage is adjusted to the
desired value.
A029Z106 (Issue 2) 43
9. Reconfiguring Voltage and Frequency 2-2010
4. To adjust voltage DOWN:

a. Press and hold START for about 1 second.
a. Voltage will decrease approximately 0.6 volts each press and release (1
second).
b. Continue to press and hold (for 1 second) START until the voltage is adjusted to the
desired value.
5. When the desired values have been set, wait about 20 seconds for the amber light to stop
blinking and then press STOP to save the adjustment.
6. Restart the genset and check the voltage.
9.2.2 Using the Cummins Onan Digital Display

1. Start the genset and let voltage and frequency stabilize for 5 to 10 seconds.
2. Rapidly press START 6 times during the first minute after startup to put the genset
controller into voltage adjustment mode. The green status light will begin blinking about
once every second and the display will indicate a status change from Running to Volt Adj.
3. To adjust voltage UP:
a. Press and quickly release START.
a. Voltage will increase approximately 0.6 volts each press and release.
b. Press and release (quickly) START until the desired value is reached.
4. To adjust voltage DOWN:
a. Press and hold START for about 1 second.
a. Voltage will decrease approximately 0.6 volts each press and release.
b. Press and release (1 second) START until the desired value is reached.
5. When satisfied with the adjustment, wait about 20 seconds for the Display to indicate a
Status change from Volt Adj. to Running and then press STOP to save the adjustment.
6. Restart the genset and check the voltage.
FIGURE 8. VOLTAGE ADJUSTMENT SCREEN
44 A029Z106 (Issue 2)
10 Installation Review and Startup
Before starting the genset, review the installation checklist below for those items that do not
require the genset to be actually running. Make necessary reconnections, modifications and
repairs. Then start and operate the genset in accordance with the Operator manual, observing
all of its instructions and precautions. Continue working through the installation checklist with
the genset running, making necessary reconnections, modifications and repairs. Check off each
item that is found to be true about the generator set. Do not place the genset in service until
each item has been checked off.
[ ] The Raw Water Pickup Test was conducted during the sea trials to establish the water line
and a siphon break was installed, if found necessary.
[ ] The sea trials established that at all boat speeds enough raw water is picked up for genset
engine and exhaust cooling.
[ ] The sea trials established that there is no backflow through the exhaust through-hull fitting or
water separator drain hose when the boat is under way, forward or reverse.
[ ] Genset compartment ventilation meets regulations and the sea trials established that
ventilation is sufficient to maintain acceptable genset compartment temperatures, even while
"heat soaking" after returning and docking.
[ ] The living quarters are sealed against leaks from spaces where exhaust and gasoline vapors
can accumulate.
[ ] The genset is securely mounted.
[ ] There is adequate clearance for conducting all maintenance specified in the Operator
manual.
[ ] The coolant recovery tank is mounted properly and is accessible for inspection and filling.
[ ] The entire exhaust system is accessible for inspection and replacement.
[ ] Fuel tanks, piping, hoses and filters comply with regulations and are accessible for inspection
and replacement.
[ ] The genset is bonded to the boat grounding system in accordance with regulations.
[ ] All grounded cranking motor circuits are connected by properly-sized common bonding
conductors.
[ ] If required, the kit for isolated DC ground was installed.
[ ] An approved transfer switch prevents interconnections between shore power and genset.
[ ] AC wiring methods, materials and bonding for grounding meet regulations.
[ ] A properly sized battery has been installed, serviced and charged. The battery is securely
mounted in an adequately ventilated space and the positive (+) terminal is shielded from
accidental contact.
[ ] The remote LCD control panel functions as intended and is not mounted where gasoline
vapors can accumulate.
[ ] Emergency and/or CO detection and shut-down devices have been connected and have
been tested to determine that the genset shuts down as intended.
[ ] The genset is properly sized for the application, the voltage and frequency are correct and
the loads across a multi-phase generator are balanced.
A029Z106 (Issue 2) 45
10. Installation Review and Startup 2-2010
[ ] Exhaust back pressure is acceptable.

[ ] The exhaust system is leak-free and conveys all engine exhaust outside, away from
windows, doors and vents.
[ ] The fuel supply system is leak-free.
[ ] The engine coolant and raw water systems are leak-free.
[ ] The engine has the proper levels of oil and coolant.
[ ] The raw water pump has been primed and the sea cock is open.
[ ] All operators have been thoroughly briefed on the Operator manual and its safety precautions
- especially concerning the dangers of carbon monoxide and gasoline vapors - and can
demonstrate how to operate, maintain and troubleshoot the genset as explained therein.
46 A029Z106 (Issue 2)
11 Specifications
TABLE 3. MODEL SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Frequency 50 Hz 60 Hz
Output Ratings 6 kW/6 kVA 7.5 kW/7.5 kVA
TABLE 4. GENERATOR SET SPECIFICATIONS TABLE
6 MDKB 7.5 MDKBJ

Installation Diagrams:
Outline drawing part number A029F006
Size Without Sound Shield:
mm (in)
Dimensions: L x W x H N/A
Size With Sound Shield: mm
(in)
Dimensions: L x W x H 664 x 583 x 535 (26.1 x 23 x 21.1)
Weight Without Sound Shield:
kg (lb)
Dry Weight N/A
Wet Weight N/A
Weight With Sound Shield: kg
(lb)
Dry Weight 195 (429)
Wet Weight 200 (442)
Sound Level With Sound
Shield: dB(A) @ 1 Meter
Sound Level 69 71
TABLE 5. ALTERNATOR SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Alternator Design Cummins Generator Technology YVB Alternator, 2-Pole Belt Drive.
See the Generator Nameplate for Rating.
Alternator Cooling Direct drive centrifugal blower fan.
TABLE 6. FUEL CONSUMPTION SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Fuel Consumption:
25% Load L/Hr (Gal/Hr) 1.12 (0.30) 1.40 (0.37)
A029Z106 (Issue 2) 47
11. Specifications 2-2010
50% Load L/Hr (Gal/Hr) 1.46 (0.39) 1.84 (0.48)

75% Load L/Hr (Gal/Hr) 1.84 (0.48) 2.33 (0.61)
100% Load L/Hr (Gal/Hr) 2.28 (0.60) 2.93 (0.77)
TABLE 7. ENGINE SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Engine Design Kubota 4-Stroke Cycle, Water Cooled Diesel with Digital Electronic Governing
Model D722
Number of Cylinders 3
Rated RPM 2400 2900
Engine Power (Max SAE 10.5 kW 11.3 kW
J1349)
Bore 67 mm (2.64 in)
Stroke 68 mm (2.68 in)
Displacement 0.719 L (43.88 in3)
Compression Ratio 23:1
Firing Order (Clockwise 1-2-3
Rotation)
Ignition Timing 21° BTDC
Valve Lash (Cold) 0.145 to 0.185 mm (0.00571 to 0.00728 in)
Required Combustion Air 0.75 m3/min (26.5 cfm) 0.91 m3/min (32 cfm)
Flow
Heat Rejection to Ambient 31 Kcal/min (124 BTU/min) 39 Kcal/min (154 BTU/min)
TABLE 8. DC ELECTRICAL SYSTEM SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Nominal Battery Voltage (DC) 12 V
Minimum Battery Capacity 450 CCA @ 32° F (° C)
Net Battery Charging 3 Amps
Alternator Current
TABLE 9. LUBRICATION SYSTEM SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Engine Oil Capacity 3 L (3.2 qt)
Engine Oil Drain Connection 3/8 NPT
Maximum Angularity:
Continuous 20°
Intermittent 30°
48 A029Z106 (Issue 2)
2-2010 11. Specifications
TABLE 10. FUEL SYSTEM SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Recommended Fuel Type Grade 2-D Diesel Fuel: Spec EN 590 or ASTM D975
Required Fuel Line Size 6.4 mm (1/4 in) I.D.
Fuel Supply Connection 1/8 NPT female
Maximum Fuel Pump Lift 1.22 m (4 ft)
TABLE 11. COOLING SYSTEM SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Recommended Coolant Type Ethylene Glycol: Spec ASTM D5345 for 50/50 Pre-Diluted Coolant
Coolant Capacity 3.1 L (3.3 quart)
Coolant Flow Rate 35 L/min (9.2 Gal/min) 29 L/min (7.7 Gal/min)
Heat Rejection to Coolant 145 Kcal/min (575 BTU/min) 180 Kcal/min (714 BTU/min)
Raw Water Inlet Connection 19.1 mm (3/4 in) I.D. Hose
Raw Water Flow Rate 15 L/min (4 Gal/min) 19 L/min (5 Gal/min)
Maximum Raw Water Pump 1.22 m (4 ft)
Lift
TABLE 12. EXHAUST SYSTEM SPECIFICATIONS TABLE
6 MDKBJ 7.5 MDKBJ

Wet Exhaust Outlet 50.8 mm (2 in) I.D. Hose
Connection
Maximum Exhaust Back 55 mm Hg (2.2 in Hg) 65 mm Hg (2.6 in Hg)
Pressure
A029Z106 (Issue 2) 49
11. Specifications 2-2010
50 A029Z106 (Issue 2)
Appendix A. Wiring Diagrams and Outline
Drawings
Table of Contents
Figure 9. Wiring Diagram (Sheet 1) ............................................................................................ 53
Figure 10. Wiring Diagram (Sheet 2) .......................................................................................... 54
Figure 11. Wiring Diagram (Sheet 3) .......................................................................................... 55
Figure 12. Control Wiring Harness ............................................................................................. 56
Figure 13. Outline Drawing .......................................................................................................... 57
A029Z106 (Issue 2) 51
Appendix A. Wiring Diagrams and Outline Drawings 2-2010
52 A029Z106 (Issue 2)
2-2010 Appendix A. Wiring Diagrams and Outline Drawings
FIGURE 9. WIRING DIAGRAM (SHEET 1)
A029Z106 (Issue 2) 53
54 A029Z106 (Issue 2)
A029Z106 (Issue 2) 55
FIGURE 12. CONTROL WIRING HARNESS
56 A029Z106 (Issue 2)
FIGURE 13. OUTLINE DRAWING
A029Z106 (Issue 2) 57
58 A029Z106 (Issue 2)
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
Copyright © 2010 Cummins Power Generation, Inc. All rights reserved.
Cummins, Onan, the "C" logo, and "Performance you rely on." are
trademarks of Cummins Inc.

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Installation Manual MDKBJ

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Installation Manual

Marine Generator Set

English - Original Instructions 2-2010 A029Z106 (Issue 2)

3. LOCATION AND MOUNTING....................................................................................................... 17

5.7 Fuel Anti-Siphon Device ........................................................................................................ 22

6. ENGINE COOLING ....................................................................................................................... 25

9. RECONFIGURING VOLTAGE AND FREQUENCY ..................................................................... 43

10. INSTALLATION REVIEW AND STARTUP.................................................................................. 45

11. SPECIFICATIONS ....................................................................................................................... 47

APPENDIX A. WIRING DIAGRAMS AND OUTLINE DRAWINGS.................................................... 51

1.1 Precaution Symbols

1.2 General Precautions

1.3 Generator Voltage Is Deadly

1.4 Engine Exhaust Is Deadly

1.5 Diesel Fuel is Combustible

1.6 Battery Gas is Explosive

1.7 Moving Parts Can Cause Severe Personal Injury Or

1.8 Flammable Vapor Can Cause A Diesel Engine To

1.9 The Hazards of Carbon Monoxide

1.9.1 What Is Carbon Monoxide Poisoning?

Mild effects of CO poisoning include:

1.9.2 What Are The Special Risks of CO on Boats?

FIGURE 1. STATION WAGON EFFECT - BOAT EXHAUST

1.9.3 Only You Can Protect Yourself From CO Poisoning!

1.10 Substance Hazardous to Health

1.10.1 Antifreeze (Fleetguard - ES Compleat/EG Premix)

1.10.2 Hazardous Reactions

1.10.3 Protective Measures

1.10.5 Emergency Action

Obtain immediate medical assistance.

1.10.6 Gas Oil

1.10.7 Hazardous Reactions

1.10.8 Protective Measures

1.10.10 Lubricant Oil - Premium Blue E 15W40

1.10.11 Hazardous Reactions

1.10.12 Protective Measures

1.10.14 Emergency Action

1.10.15 Emergency Action

1.10.16 Substance Hazardous to Health

1.11 Generator Set Warning Labels

Caution/Warning Indicates a risk of personal injury

Caution/Warning of Temperature Hazard.

Caution/Warning of High Voltage Hazard.

Caution/Warning of Engine Coolant Pressure Hazard.

Caution/Warning of Combustion/Explosion Hazard.

Caution/Warning of Belt and Rotating Part Hazard.

Caution/Warning of Chemical (ingestion/burn) Hazard.

Caution/Warning of High Voltage or Current Source Hazard.

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2.2 Standards for Safety

National Fire Protection Association

2.3 Outline Drawings

2.5 Electromagnetic Compatibility

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3.1 Lifting The Generator Set

· Resetting the line circuit breakers

3.3 Mounting The Generator Set

4.1 Ventilation Exhaust System

4.2 Carbon Monoxide (CO)

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5.2 Fuel Inlet Fitting

5.3 Fuel Lines and Hoses

5.4 Fuel Filters