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1. NEMA Class Ambient 40 C Insulation REFER TO OPERATOR S MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS 0000000 00000001 000000 0000006 0000080 no MODEL NUMBER SERIAL NUMBER FIGURE 1 1 TYPICAL NAMEPLATE HOW TO OBTAIN SERVICE For generator set parts service and product infor mation such as the Service Manual contact the nearest authorized Cummins Onan distributor You may go to Internet site www cumminsonan com for information for contacting our distributors world wide In North America Call 1 800 888 6626 for the nearest Cummins Onan distributor in the United States or Canada Press 1 OPTION 1 to be automatically connected If you are unable to contact a distributor using the automated service consult the Yellow Pages Typi cally our distributors are listed under GENERATORS ELECTRIC Outside North America Call Cummins Power Generation at 1 763 574 5000 from 7 30 AM to 4 00 PM Cen tral Standard Time Monday through Friday or fax 1 763 528 7229 Information To Have Available 1 Model Number including Spec Letter and Seri al Number Figure 1 1 2 Date of purchase 3 Nature of problem Section 5 Troubleshoot ing 1 2 EMISSIONS LABEL The label that states compliance with applicable en gin
2. To Fig 2 7 FIGURE 2 3 TYPICAL GENERATOR SET STATUS SCREENS 2 4 Fault Screen If a fault shutdown occurs the Alarm status lamp will blink and the Digital Display will display a de scription of the Fault the numeric Fault code and the accumulated number of hours of generator set operating time when the Fault occurred Fig ure 2 4 Refer to TABLE 5 1 TROUBLESHOOT ING GENERATOR SET FAULTS to diagnose and correct the problem The Digital Display will display the fault indefinitely Touch any button to clear the fault The Digital Dis play will turn off in 5 minutes after the fault has been cleared Press BACK to get back to GEN STATUS 2 5 FAULT Speed Sense Lost Fault No 45 Hour 10000 1 FIGURE 2 4 TYPICAL DIGITAL DISPLAY FAULT SCREEN Fault History To display any of the last five faults press FAULT on any GEN STATUS screen and HIST on the FAULT screen Figure 2 5 The FAULT HISTORY screen displays a description of the Fault the numeric Fault code and the accu mulated number of hours of generator set operating time when the Fault occurred Press the up or down arrow to display an earlier or later fault If there are no faults the FAULT HISTORY screen will display No Stored Faults Press BACK to get back to GEN STATUS Engine Pre Alarms When either engine oil pressure or coolant tempera ture approaches its engine shutdown limit the Pre Alarm status lamp will light
3. DIGITAL DISPLAY PANEL The Cummins Onan Digital Display panel has an LCD screen with 4 navigation buttons 3 status lamps a START button and a STOP button Fig ure 2 2 Turning On the Digital Display Panel Touch any button to turn on the Digital Display pan el which will then establish communications with the generator set All connected Digital Display pan els will turn on automatically when the generator set is started at any station They will all turn off 5 min utes after the generator set has received a normal command to stop If a fault occurs they will stay on until the fault is cleared by touching any button on any Digital Display panel Start Button Push and Hold START until the generator set starts The Generator status lamp will blink while the en gine is preheating and cranking and stay on while the generator set is running Status on the Digital Display will change from Starting to Running Fig ure 2 3 See STARTING THE GENERATOR SET p 3 3 Stop Button To Stop the Generator Set Push and Release STOP The Generator status lamp will go out Sta tus on the Digital Display will change from Running to Stopped See STOPPING THE GENERATOR SET p 3 4 2 3 To Prime Fuel Push and Hold STOP for at least 30 seconds The Generator status lamp will blink Sta tus on the Digital Display will change to Priming in 2 seconds See PRIMING THE FUEL SYSTEM p 3 3 Generator Set Status Lamps Generator
4. Part 1 Compression ignition engines Reciprocating internal combustion engine driven Bo SN IATER generating sets Safety BS EN 1679 1 1998 1 5 2 Control Panel REMOTE CONTROL AND MONITORING Remote Control Panels The boat may be equipped with one or more remote control panels for generator set control and moni toring A remote control panel may consist of a con trol switch and status lamp or a Cummins Onan Dig ital Display panel See Page 2 3 for instructions on how to use the Digital Display panel Boat Monitoring System Generator set operation may also be monitored by an integrated boat equipment monitoring system that uses SAE J1939 or SmartCraft network proto col LOCAL CONTROL PANEL The local control panel Figure 2 1 has the follow ing components Control Switch Status Lamps Standard The control switch is used to start and stop the gen erator set and prime fuel It has two status lamps green and amber e Push and Hold START to preheat crank and start the generator set The Amber status lamp flashes rapidly during preheat and cranking Preheat is the period of time prior to engine cranking when the glow plugs preheat the com bustion chambers The time is automatically varied by the generator set controller on the ba sis of engine temperature e Push and Release STOP Prime to stop the generator set SmartCraft is a trademark of the Brunswick Corporation 2 1 e Push and H
5. This status lamp green blinks while the engine is cranking or the fuel system is being primed It stays on while the generator set is run ning Pre Alarm This status lamp amber lights and stays on while an engine Pre Alarm condition exists p 2 6 Alarm This status lamp red blinks during a fault shutdown p 2 5 8 Generator Pre Alarm Alarm START STOP X e FIGURE 2 2 DIGITAL DISPLAV PANEL Generator Set Status Generator set status is displayed on three GEN STATUS screens Figure 2 3 GEN STATUS Pg1 GEN STATUS Pgl appears when the Digital Display is turned on Press Status Starting the double arrow to go to the next screen AC Volts 120V AC Freq 60Hz Status on GEN STATUS Pg1 displays the word Priming Starting Running Stopped or Volt ETUPIFASLTISCREE Adj depending on the operating status of the gen erator set The rest of the information on the three status screens includes AC output voltage AC fre quency engine coolant temperature engine oil GEN STATUS pressure starting battery voltage and the accumu Cool Temp 123F lated number of hours of generator set operating c H time Oil Press Sl H ETUP FAULT SCREE TUS Batt Volt 12 5V Hr Meter 12345 6 ETUP FAULT SCREF
6. Zinc Anode Replace the zinc anode as recommended Table 4 1 Use thread sealant on the zinc plug and drain plugs and replace the clean out cover gaskets if the old ones are torn or otherwise damaged Siphon Break See Table 4 1 for scheduled maintenance A siphon break is installed when the exhaust water mixer is below the water line If of a spring loaded valve de sign check for free movement of the plunger Re place the device if the plunger does not move freely or the body is encrusted with deposits from leakage past the valve seat If of the bleed vent type check that the vent hose is properly connected on both ends If the vent is connected to a through hull fit ting check for normal water flow whenever the en gine is running See the Installation Manual for more information regarding siphon break installation Bypassing a siphon break or failing to maintain it can lead to engine flooding and damage to the engine not covered under War ranty EXHAUST SWITCH RAW WATER e EXHAUST WATER MIXER WITH HIGH TEMPERATURE LEFT SIDE EXHAUST amp RAW WATER OUT TO BULKHEAD FITTING ON RIGHT OR RAW WATER HOSE TO EXHAUST WATER MIXER WHEN REQUIRED REPLACE WITH SIPHON BREAK AND CONNECTING HOSES IY 24 2 J J 22 2 L Leg 12 N ST Ter NECK FILL NECK HAS HOSE BARB FOR CONNECTING COOLANT RECOVERY TANK ES A WITH PRESSURE CAP AND COOLANT FILL EXHAUST MANIFOLD amp COOLANT RESERVOIR BLOCK DR
7. CODE NO 57 A local or remote control switch was held in the Prime position for more than 5 minutes Corrective Action Check for and remove any object that may be holding any control switch local or remote in the prime position HIGH EXHAUST TEMPERATURE CODE NO 58 Exhaust temperature exceeded design limits due to lack of water delivered to the exhaust water mixer Corrective Action 1 Check for and clean a blocked sea water strainer If above the water line fill the strainer with water to assist priming 2 Inspect the siphon break if provided for proper operation 3 Check for a worn raw water impeller and replace as necessary p 4 12 4 Clean the heat exchanger p 4 8 LOW COOLANT LEVEL CODE NO 59 The engine coolant level fell below the optional coolant level sensor Corrective Action Add coolant as necessary and repair leaks EXTERNAL SHUTDOWN CODE NO 61 The generator set was shut down by a fire suppression system or other external control Corrective Action Make all necessary repairs to the generator set and connected equipment and re set the external control which shut down the generator set 5 8 If you are still unable to resolve the problem contact an authorized Cummins Onan service representa tive See How to Obtain Service p 1 2 5 9 6 Specifications ALTERNATOR Single Bearing Brushless 4 Pole Rotating Field with Digital Electronic Regulation See Generator Set Nameplate for Rat
8. Heat Rejection to Coolant 60 Hz 950 Btu min 239 kcal min 950 Btu min 239 kcal min 1420 Btu min 358 kcal min 1420 Btu min 358 kcal min 50 Hz 780 Btu min 197 kcal min 780 Btu min 197 kcal min 1160 Btu min 292 kcal min 1160 Btu min 292 kcal min Thermostat Opening Temperature 185 F 85 C BATTERIES Nominal Battery Voltage 12 volts 24 volts optional Min CCA Raino SAE G 32 FOT 500 amps Batey Charge 1824 VOC S70 amps SIZE WEIGHT NOISE Without Enclosure Dry Weight 525 Ibs 238 kg 555 Ibs 252 kg 640 Ibs 290 kg 640 Ibs 290 kg Dimensions L x W x H 32 4 x 18 9 x 22 1 in 35 9 x 22 3 x 23 0 in 40 7 x 22 3 x 23 0 in 40 7 x 22 3 x 23 0 in 823 x 479 x 560 mm 911 x 566 x 585 mm 1033 x 566 x 585 mm 1033 x 566 x 585 mm With Enclosure Noise 66 65 dB A 60 50HZ 66 65 dB A 60 50HZ 66 65 dB A 60 50HZ Dry Weight 600 Ibs 272 kg 695 Ibs 315 kg 695 Ibs 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 ALTERNATOR Single Bearing Brushless 4 Pole Rotating Field with Digital Electronic Regulation See Generator Set Nameplate for Rating FUEL CONSUMPTION Half Load 0 9 Gal hr 3 3 L hr 1 0 Gal hr 4 0 L hr 1 2 Gal hr 4 4 L hr Half Load 0 7 Gal hr 2 7 L hr 0 9 Gal hr 3 4 L hr 1 0 Gal hr 3 9 L hr ENGINE Kubota 4 Stroke Cycle Indirect Injection Water Cooled Diesel with Digital Electro
9. Troubleshooting with Status 5 1 n nmm f RR 6 1 MAINTENANCE RECORD 7 1 SAFETY PRECAUTIONS Thoroughly read the OPERATOR MANUAL be fore operating the generator set Safe operation and top performance can only be obtained when equipment is operated and maintained properly Only trained and experienced service person nel with knowledge of fuels electricity and ma chinery hazards shall remove dismantle and dispose of the generator set See service manu al Some generator set installation procedures present hazards that can result in severe per sonal injury or death Only trained and experi enced personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set installation procedures The following symbols in this manual alert you to potential hazards to the operator service person and equipment Used to alerts 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 Used to alert you to a hazard or un safe practice that can result in severe personal injury or death Used to alert you to a hazard or un safe practice that can result in personal injury or equipment damage Electricity fuel exhaust moving parts and batter ies present hazards which can
10. 0 Gal min 18 9 L min Combustion Air Flow 60 Hz 30 ft3 min 0 85 m3 min 30 ft3 min 0 85 m3 min 41 ftS min 1 16 m3 min 41 ft3 min 1 16 m3 min 50 Hz 25 ft3 min 0 71 m3 min 25 ft3 min 0 71 m3 min 34 ft3 min 0 95 m3 min 34 ft3 min 0 96 m3 min Heat Rejection to Ambient 60 Hz 200 Btu min 50 kcal min 200 Btu min 50 kcal min 280 Btu min 71 kcal min 280 Btu min 71 kcal min 50 Hz 179 Btu min 45 kcal min 179 Btu min 45 kcal min 210 Btu min 53 kcal min 210 Btu min 53 kcal min 10 Continuous 22 5 Intermittent No 2 D Diesel Fuel Spec EN 590 or ASTM D975 Ethylene Glycol Spec ASTM D5345 for 50 50 Prediluted Coolant or Recommended Coolant ASTM D4985 for Concentrated Coolant with 4096 to 6096 quality water CONNECTIONS Max Fuel Pump Uf aman i Maximum Angularity Recommended Fuel 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 Raw Water ine Tin 254 mn ID Hose Wet Exhaust Out Zin 608 mm ID Hose Dry Exhaust Exhaust Back Pressure 76 mn Ha 4 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 KEEL COOLING Coolant Inlet amp 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
11. 5 20 5 amps 60 50 Hz 24 volts 22 5 20 5 amps 60 50 Hz 12 volts 43 0 40 0 amps 60 50 Hz 12 volts 43 0 40 0 amps 60 50 Hz Net Battery Charging Isolated Ground 24 volts 30 5 28 5 amps 60 50 Hz 24 volts 30 5 28 5 amps 60 50 Hz SIZE WEIGHT NOISE Without Sound Shield Dry Weight 1245 lbs 565 kg 1300 Ibs 590 kg Dimensions L x W x H 53 5 x 24 5 x 28 8 in 1358 x 622 x 731 mm 53 5 x 24 5 x 28 8 in 1358 x 622 x 731 mm With Sound Shield Noise 68 67 dB A 60 50 HZ 68 67 dB A 60 50 HZ Dry Weight 1325 Ibs 601 kg 1380 Ibs 626 kg Dimensions L x W x H 53 5 x 24 5 x 30 0 in 1358 x 622 x 761 mm 53 5 x 24 5 x 30 0 in 1358 x 622 x 761 mm 7 Maintenance Record Record all periodic and unscheduled maintenance and service See Periodic Maintenance Section 4 HOUR METER MAINTENANCE OR SERVICE PERFORMED a Record the name address and phone number of your authorized Cummins Onan service center Cummins Onan 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 logo and Performance you rely on are trademarks of Cummins Inc 2010 Cummins Power Generation Inc All rights reserved
12. Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines Remove combustion air or exhaust system blockages Check all fuel fittings for fuel and air leaks and tighten as necessary Replace fuel filters p 4 6 Check for contaminated fuel by connecting to a source of known fuel quality FAULTY OIL PRESSURE SENDER CODE NO 23 Controller sensed grounded sender Corrective Action See an authorized Cummins Onan service representative 5 5 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting FAULTY TEMPERATURE SENDER CODE NO 24 Controller sensed open sender Corrective Action See an authorized Cummins Onan service representative LOSS OF AC VOLTAGE SENSE CODE NO 27 The generator set Controller lost VAC sensing during normal voltage regulation when the field was functioning normally and frequency was
13. Coolant with 4096 to 6096 quality water CONNECTIONS Max Fuel Pump Uf 21 Fuel Supply TA NPT female Fuel Return V NPT female Max Raw Water Pump Ui 122 Raw Water lt Ti 25 4 mn ID Hose Wet Exhaust Outlet 2 in 60 8 mm ID Hose Dry Exhaust Outlet TIBNPT Max Exhaust Back Pressure 76 mm Fo KEEL COOLING Coolant Inlet amp 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 1590 Btu min 402 kcal min 1980 Btu min 500 kcal min 1980 Btu min 500 kcal min 50 Hz 1500 Btu min 379 kcal min 1670 Btu min 422 kcal min 1670 Btu min 422 kcal min Thermostat Opening Temperature 185 F 85 C 185 F 85 C 185 F 85 C BATTERIES Nominal Battery Voltage 12 volts 24 volts optional GCA ating SAE DH FOO G Batey Chang 0 1724 VOC AGO aps SIZE WEIGHT NOISE ithout Enclosure Dry Weight 830 lbs 377 kg 870 lbs 395 kg 870 Ibs 395 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 44 4 x 23 7 x 26 1 in 1127 x 602 x 672 mm 1127 x 602 x 672 mm 1127 x 602 x 672 mm With Enclosure Noise 67 64 dB A 60 50 HZ 67 64 dB A 60 50 HZ 67 64 dB A 60 50 HZ Dry Weight 890 Ibs 404 kg 930 Ibs 422 kg 930 Ibs 422 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 44 4 x 23 7 x 27 5 in 1127 x 602 x 698 mm 1127 x 602 x 698 mm 11
14. HEAT EXCHANGER TO COOLANT PUMP LOCATION RAW WATER FLOW SWITCH 29 a Voy HOSE RAW WATER PUMP TO HEAT EXCHANGER HEAT EXCHANGER MOUNTING STRAPS 2 TORQUE TO 8 FT LB 11 gt COOLANT DRAIN VALVE HEAT EXCHANGER WITH CLEANOUT RAW WATER COOLANT 2 COVERS TOP amp BOTTOM DRAIN PLUG RAW WATER Replace hose with siphon break and connecting hoses when required For dry exhaust replace with hose to hull fitting FIGURE 4 6 ENGINE COOLING SYSTEM HOSES HEAT EXCHANGER RAW WATER PUMP MDKBT MDKBU 5 Troubleshooting Use TABLE 5 1 TROUBLESHOOTING GEN ERATOR SET FAULTS in conjunction with the Digi tal Display or blinking control switch status lamp to troubleshoot the generator set Perform the step by step corrective actions suggested If you are still unable to resolve the problem contact an autho rized Cummins Onan service representative See How to Obtain Service p 1 2 Note Many generator set shutdowns can be avoided by performing periodic maintenance on schedule TABLE 4 1 PERIODIC MAINTENANCE SCHEDULE and by not running the generator set out of fuel Note that when generator sets and propulsion engines draw from the same fuel tanks the fuel pickup tubes are usually arranged so that the generator sets run out of fuel first By marking the generator set empty points on the fuel gauges it will be easier to tell when to stop the generator sets before r
15. It has a boiling point greater than 150 C a flash point Open Cup of 220 C Cleveland and is insol uble 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 en gines operating under severe conditions Installers operators and maintainers are likely to encounter this product HAZARDOUS REACTIONS This product is stable although slightly re active with oxidising agents Results of decomposition are carbon oxides CO 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 prod ucts 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 not breathe vapour spray PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Adopt a high standard of personal hygiene In case of skin contact wash thoroughly with soap and wa ter Use safety glasses impervious gloves and lab coat Avoid contamination inside the gloves If overalls become contaminated discontinue use and clean thoroughly No special respiratory precautions are necessary in normal use Do no breathe vapour spray when handling hot materials STOR
16. RECOMMENDATIONS Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning equip ment 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 fire extinguisher handy High quality diesel fuel is necessary for good perfor mance and long engine life e The specifications for the type and sulfur con tent ppm weight of the diesel fuel used must comply with all emissions regulations ap plicable in the areas where the genset is to be operated e Diesel fuels meeting ASTM D975 or EN 590 specifications are recommended Use Grade 1 D diesel fuel where ambient temperatures are below 14 F 10 C A minimum Fuel Ce tane Rating of 45 is recommended Where am bient temperatures are below 4 F 20 C or the elevation is above 5000 ft 1500 m a mini mum Cetane Rating of 50 is recommended e Current US EPA regulations for Non Road en gines limit diesel fuel sulfur content to a maxi mum of 500 ppm 0 05 weight Therefore use Grade 2 D S500 or 2 D S15 diesel fuel Where ambient temperatures are below 14 F 10 use Grade 1 D S500 or 1 615 die sel fuel Note that beginning in year 2010 US EPA regulations for Non Road engines will limit diesel fuel sulfur content to a maximum of 15 ppm 0 001596 weight e Do not use diesel fuel havi
17. and appliances when ambient temperatures are higher than normal TABLE 3 1 TYPICAL APPLIANCE LOADS NO LOAD OPERATION Keep no load operation to a minimum During no load operation cylinder temperatures drop to the point where fuel does not burn completely causing fuel wetting and white smoke It is best to run the generator set at 1 4 to 3 4 load RESETTING LINE CIRCUIT BREAKERS Connecting too many electrical loads and ap pliances can trip the line circuit breakers on the gen erator set or on the boat s power distribution panel Note that the generator set will continue to run if its circuit breaker trips If a circuit breaker trips disconnect or turn off as many electrical loads and appliances as possible Then reset the circuit breaker and reconnect the loads and appliances one by one making sure not to overload the generator set or cause a circuit breaker to trip An electrical load or appliance probably has a short if it trips a circuit breaker immediately when it is con nected Electrical equipment must be used and maintained properly and be properly grounded to cause the line circuit breakers to trip when short cir cuits occur Short circuits in electrical equip ment can cause fire and electrical shock leading to severe personal injury or death Electrical equipment and its grounding must be main tained properly to protect against short circuits CONNECTING TO SHORE POWER When provisions have been made fo
18. and the PRE ALARM screen will display Low Oil Pressure or High En gine Temperature Figure 2 6 Press BACK to get back to GEN STATUS to monitor engine temperature and oil pressure and service the generator set as required From FAULT Fig 2 3 FAULT No Active Faults HIST FAULT HISTORY Speed Sense Lost 45 Hours 10000 1 sack MAE OR FAULT HISTORY No Stored Faults FIGURE 2 5 FAULT HISTORY From FAULT Fig ao FAULT Eng coolant temp sensor fault Fault No 24 PRE ALARM Low Oil Pressure see Status Page 2 for more info OR Active Alarms ABACK FIGURE 2 6 ENGINE PRE ALARMS 2 6 Brightness and Contrast Press SCREEN on any GEN STATUS screen Press NEXT on the SCREEN ADJUST screen to se lect Brightness or Contrast Figure 2 7 Press the right or left arrow to increase or decrease brightness or contrast Note Contrast applies only to the LCD screen Press the BACK button to save the settings and get back to GEN STATUS Display Setup Press SETUP on any GEN STATUS screen Press the up or down arrow on the SETUP screen to select DISPLAY SETUP and press ENTER Figure 2 8 To select the units of measure for the GEN STATUS Screens press NEXT on the DISPLAY SETUP screen to select Units and then the up or down ar row to select or Metric Press BACK to save the selection and get back t
19. breathing apparatus Keep fire ex posed containers cool using water fog spray Prevent run off from entering waterway drains and drinking water supplies e Ingestion Do not induce vomiting Wash the mouth out with water and send to hospital immediately e Inhalation of vapour Remove from further exposure Obtain medi cal assistance immediately e Aspiration inhalation of liquid If following ingestion of gas oil vomiting oc curs there is danger of aspiration into the lungs This would cause intense local irritation and chemical pneumonitis that can be fatal Obtain immediate medical assistance e Eyes Irrigate copiously with water or preferably eye wash solution for at least five minutes If irrita tion persists seek medical advice e Skin Wash thoroughly with soap and water Change clothing if necessary If high pressure injection has occurred prompt surgical attention is required e Spillage Absorb using sand earth or other suitable ma terial Dispose of unwanted or absorbed flam mable material as directed under Storage Transport LUBRICATION OIL PREMIUM BLUE E 15W40 Also known as oil lube oil sump oil new oil is dark viscous liquid with a slight characteristic odour The base oil contains distillates petroleum sol vent dewaxed heavy paraffinic It is not classified as dangerous according to Directive 1999 45 EC and its amendments and is not classified accord ing to the EU regulations
20. ce c EUM DER E REA TEE 3 2 5 E ae 3 2 Fire Extinguisher Bor es D ae wen ee des 3 2 Pre SAN CHECKS MU cs uo eu ET 3 3 Priming the Fuel System cese die 3 3 Startingithe Generator 3 3 Stopping the Genreriogs Et 3 4 Emergency Stop saver Lil bba iet ti diesel 3 4 Loading the Generator Set 3 4 No Load Operation 4 2 eee Rx RR ER RO RO DR om RR PER ORG seen 3 5 Resetting Line Circuit Breakers 3 5 Connecting to Shore Power 3 5 Cold Temperature 3 6 Care of New or Re Built Engine 3 6 Exercising the Generator Set 3 6 Storing the Generate EE 3 6 4 PERIODI GA A 720 4 1 4 2 Maintaining the Battery and Battery Connections 4 2 hneckingrEn ime Oil 0 En E 4 3 qe uL 4 3 Draining Replacing Fuel Filters 4 6 Maintaining the Engine Cooling System 4 7 SATROWBEESHOOMNG 050 500 5 1 Troubleshooting with Digital Display 5 1
21. exhaust leaks e To prevent accidental or remote starting while working on the generator set disconnect the negative battery cable at the battery e 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 e Keep the generator set drip pan and compart ment clean Oily rags can catch fire Gear stowed in the compartment can restrict cool ing e Make sure all fasteners are secure and proper ly torqued e Do not work on the generator set when mental ly or physically fatigued or after having con sumed alcohol or drugs e 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 e Ethylene glycol used as engine coolant is tox ic to humans and animals Clean up spills and dispose of used engine coolant in accordance with local environmental regulations e Keep multi purpose fire extinguishers handy Multi purpose fire extinguishers are used for fires that involve ordinary combustible materi als such as wood and cloth combustible and flammable liquid fuels and gaseous fuels live electrical equipment North America or US Ref NFPA No 10 e Generator set installation and operation must comply with all applicable local state and fed eral codes and regulations e Generator sets with a sound shi
22. ft3 min 2 2 m3 min 76 5 ft3 min 2 2 m3 min Heat Rejection to Ambient 60 Hz 532 Btu min 134 kcal min 629 Btu min 159 kcal min 0 Hz 441 Btu min 111 kcal min 515 Btu min 130 kcal min Maximum Angularity 10 Continuous 22 5 Intermittent Recommended Fuel No 2 D Diesel Fuel Spec EN 590 or ASTM D975 Ethylene Glycol Spec ASTM D5345 for 50 50 Prediluted Coolant or Recommended Coolant ASTM D4985 for Concentrated Coolant with 4096 to 6096 quality water CONNECTIONS Max Fuel Pump Uf AD 1 a I 4 Fuel Supply 1 4 NPT female 1 4 NPT female Fuel Return 1 4 NPT female 1 4 NPT female Max Raw Water Pump Lift 4 ft 1 22 m 4 ft 1 22 m Raw Water Inlet 1 25 in 31 7 mm ID Hose Wet Exhaust Outlet 3 in 76 2 mm ID Hose Dy Exhaust Out Zin NPT Max Exhaust Back Pressure 3 in 76 mm Hg KEEL COOLING Coolant Inlet amp Outlet 1 25 in 31 7 mm ID Hose 1 25 in 31 7 mm ID Hose Max Coolant Friction Head 1 psi 6 9 kPa 1 psi 6 9 kPa Heat Rejection to Coolant 60 Hz 2200 Btu min 555 kcal min 2600 Btu min 655 kcal min 50 Hz 1870 Btu min 470 kcal min 2200 Btu min 555 kcal min Thermostat Opening Temperature 170 F 76 5 C 170 F 76 5 C BATTERIES Nominal Battery Voltage 12 volts 24 volts optional 12 volts 24 volts optional Min CCA Rating SAE 32 F 0 C 625 amps 625 amps 12 volts 30 0 22 0 amps 60 50 Hz 12 volts 30 0 22 0 amps 60 50 Hz Net Battery Charging Negative Ground 24 volts 22
23. other sources of ignition well away e Fuel lines must be secured free of leaks and separated or shielded from electrical wiring MOVING PARTS CAN CAUSE SEVERE PERSONAL INJURY OR DEATH e Do not wear loose clothing or jewelry near moving parts such as PTO shafts fans belts and pulleys e Keep hands away from moving parts e Keep guards in place over fans belts pulleys and other moving parts BATTERY GAS IS EXPLOSIVE e Wear splash proof safety glasses e Do not smoke or permit flames or sparks to oc cur near the battery at any time e To reduce arcing when disconnecting or necting battery cables always disconnect the negative battery cable first and reconnect it last FLAMMABLE VAPOR CAN CAUSE A DIESEL ENGINE TO OVERSPEED Do not operate a diesel powered generator set where a flammable vapor envi ronment 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 genera tor set safely GENERAL PRECAUTIONS e Keep children away from the generator set e Do not use evaporative starting fluids They are highly explosive e Do notstep 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
24. second set of blinks the units digit of the shutdown code number For example Low Voltage Code No 13 appears as blink pause blink blink blink ong pause re peat e Four blinks indicate shutdown due to a failure to start within the time allowed for cranking e Five blinks indicate shutdown due to high lev els of Carbon Monoxide CO in the vessel e Seven blinks indicate shutdown due to a loss of raw water flow for engine and exhaust cool ing Blinking continues for five minutes and stops To re store blinking press the control switch to STOP Prime until the lamp comes on 3 to 4 seconds Then press STOP Prime three times to restores blinking Note The last fault logged will blink even though the condition that caused the shutdown may have been corrected TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS Some generator set service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting NO RESPONSE AT DIGITAL DISPLAY OR CONTROL SWITCH Faulty switch poor or missing connections dead battery Corrective Action 1 Push
25. the Emergency Stop and or DC Circuit Breaker ON if tripped 2 Try the Digital Display or control switch on the generator set local if there is no response at a re mote Display or control switch and vice versa 3 If none of the Displays or control switches works service as necessary by cleaning and tightening battery connections recharging or replacing the battery or replacing damaged battery cables p 4 2 THE STARTER ENGAGES AND DISENGAGES Low cranking voltage Corrective Action 1 De energize the PTO clutch if so equipped 2 Service as necessary by cleaning and tightening battery connections recharging or replacing the battery or replacing damaged battery cables p 4 2 THE STARTING BATTERIES DO NOT MAINTAIN A CHARGE Marginal battery battery connections or charging system Corrective Action 1 Service as necessary by cleaning and tightening battery connections recharging or replacing the battery or replacing damaged battery cables p 4 2 2 Check for and disconnect parasitic battery loads NO AC POWER WHEN GENERATOR SET IS RUNNING A Circuit Breaker is OFF tripped or malfunctioning or the generator is not connected properly Corrective Action 1 Reset turn ON or repair the generator set circuit breaker as necessary 2 Reset turn ON or repair any other circuit breaker in the AC power supply system as necessary 5 2 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set serv
26. 27 x 602 x 698 mm MDKBT Bd ALTERNATOR Single Bearing Brushless 4 Pole Rotating Field with Digital Electronic Regulation See Generator Set Nameplate for Rating FUEL CONSUMPTION 60 Hz Full Load 2 5 Gal hr 9 5 L hr 3 0 Gal hr 11 2 L hr Half Load 1 5 Gal hr 5 7 L hr 1 5 Gal hr 5 6 L hr 50 Hz Full Load 2 1 Gal hr 8 0 L hr 2 4 Gal hr 9 1 L hr Half Load 1 5 Gal hr 5 6 L hr 1 5 Gal hr 5 7 L hr ENGINE Kubota 4 Stroke Cycle Indirect Injection Water Cooled Diesel with Digital Electronic Governing V3300 E2B V3300 E2B Number oi Gyinders Displacement 202 48 in3 3318 cm3 202 48 in3 3318 cm3 Stroke 4 33 in 110 mm 4 33 in 110 mm Compression Ratio 22 5 1 22 5 1 i Bore 3 86 in 98 mm 3 86 in 98 mm Firing Order Clockwise Rotation 1 3 4 2 1 3 4 2 Fuel Injection Timing 12 BTDC 12 BTDC 0 009 0 010 in 0 009 0 010 in Valve Lash cold 0 23 0 27 mm 0 23 0 27 mm Lube Oil Capacity 11 quart 10 4 L 11 quart 10 4 L 10 Lube Oil Drain Connection 3 8 NPT 3 8 NPT Coolant Capacity 14 5 quart 13 7 L 14 5 quart 13 7 L Coolant Flow Rate 60 Hz 14 0 Gal min 53 0 L min 14 0 Gal min 53 0 L min 50 Hz 11 5 Gal min 43 5 L min 11 5 Gal min 43 5 L min Raw Water Flow Rate 60 Hz 15 6 Gal min 59 1 L min 15 6 Gal min 59 1 L min 50 Hz 13 0 Gal min 49 2 L min 13 0 Gal min 49 2 L min Combustion Air Flow 60 Hz 91 7 2 6 m3 min 91 7 2 6 m3 min 50 Hz 76 5
27. AGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers tightly sealed when not in use Keep in a cool well ventilated area out of sun light 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 au thorised contractor to a licensed site Finish clean ing by spreading water on the contaminated sur face and allow to evacuate through the sanitary system EMERGENCY ACTION e Fire Extinguishing media Large fire Use water spray fog or foam Do not use water jet Small fire Use dry chemical powder Fire fighters to use self contained breathing apparatus and full turnout gear Keep fire ex posed containers cool Ingestion Do not induce vomiting Obtain medical advice immediately Inhalation of vapour Remove from further exposure Obtain medi cal attention vi Aspiration inhalation of liquid Obtain immediate medical assistance Eyes Flush copiously with water or preferably eye wash solution for at least fifteen minutes Ob tain 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 Gen
28. AIN VALVE COOLANT COVER BOTH ENDS 2 o 2 lt ui 1 tr m lt z z tr RAW WATER IN FROM BULKHEAD FITTING ON RIGHT OR LEFT SIDE RAW WATER DRAIN PLUG BOTH ENDS g TS LEVEL SENSOR LOCATION COOLANT THERMOSTAT OPTIONAL LOW COOLANT COOLANT PUMP RAW WATER PUMP COOLANT DRAIN VALVE FIGURE 4 4 ENGINE COOLING SYSTEM MDKBK MDKBL MDKBM MDKBN 4 9 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 COOLANT PUMP PULLEY RAW WATER HOSE TO EXHAUST WATER MIXER WHEN REQUIRED ZA NDA LOCATION BLOCK REPLACE WITH SIPHON DRAIN VALVE BREAK AND CONNECTING i COOLANT HOSES ZINC ANODE EXHAUST WATER MIXER WITH HIGH TEMPERATURE EXHAUST SWITCH EXHAUST amp RAW WATER OUT TO BULKHEAD FITTING ON RIGHT OR LEFT SIDE RAW WATER CLEANOUT COVER COOLANT DRAIN VALVE BOTH ENDS MAKE SURE TO COOLANT gt RAW WATER PLUGS RECONNECT GROUND STRAP ON UNDERNEATH THIS END WITH COVER SCREW RAW WATER FIGURE 4 5 ENGINE COOLING SYSTEM MDKBP MDKBR MDKBV 4 10 HOSE THERMOSTAT TO COOLANT RESERVOIR HOSE RAW WATER TO EXHAUST WATER MIXER HOSE COOLANT FR RESERVOIR TO Ca HEAT EXCHANGER HOSE
29. ATTERY AND BATTERY CONNECTIONS p 4 2 3 Replace the raw water pump impeller if it was installed more than a year ago p 4 12 Perform the maintenance required p 4 1 conduct the pre start checks and prime the fuel system Start and run the generator set 6 Turn on the generator set line circuit breaker when ready to power loads 4 Periodic Maintenance Periodic maintenance is essential for top perfor mance and long generator set life Use Table 4 1 as a guide for normal periodic maintenance Maintenance replacement or repair of emission control devices and systems may be performed by any engine repair establishment or individual How ever warranty work must be completed by an au thorized Cummins Onan service representative To help you keep generator set maintenance regu lar and provide a basis for warranty claims record maintenance performed in Maintenance Record Section 7 Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable at the battery to pre vent starting while working on the generator set TABLE 4 1 PERIODIC MAINTENANCE SCHEDULE MAINTENANCE OPERATION Gereral speci Eq ES Check V Belt Check V Belt TensionS Inspect EM Inspect Siphon Break Replace Fuel Filters Replace Fuel Filters Filters Inspect Zinc Anode Be Replace Raw ware EL MAINTENANCE FREQUENCY Every
30. CAUTION Too little oil can cause severe en gine damage Too much oil can cause high oil consumption Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Shut off the generator set and check the oil level with the dip stick Figure 4 1 4 2 or 4 3 Add or drain oil as necessary Add 1 quart 0 9 liters when the level falls to the ADD mark Drain oil if the level is above the full mark See ENGINE OIL RECOMMENDATIONS p 3 1 CHANGING ENGINE OIL AND FILTER Refer to Table 4 1 for scheduled engine oil change 1 Run the generator set under load until it is up to operating temperature stop it and disconnect the negative battery cable at the battery Accidental or remote starting can cause severe personal injury or death Disconnect the negative cable at the bat tery to prevent the engine from starting 4 3 Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended 2 Be reagy to drain the oil into a suitable contain er and then open the drain valve or unscrew the plug on the end of the drain hose Figure 4 1 4 2 or 4 3 and drain the oil into a suitable con tainer Two wrenches are necessary to keep from twisting the hose when loosening and tightening the plug If an oil pump out system is installed follow the instructions provided Secure the drai
31. Every BUD 5 Years Page SET gt ssl m I olJ N P gt O o sewes ES E Replace Coolant Pressure inspect Generator Bearings EE 1 Includes inspection of Oil Level Coolant Level Fuel System Exhaust System Batteries and Battery Connections 2 See battery manufacturer s recommendations 3 Check for slippage cracking and wear 4 Perform twice as often when using high sulfur fuel See ENGINE OIL RECOMMENDATIONS Page 3 1 5 Must be performed by a qualified mechanic authorized Cummins Onan dealer GENERAL INSPECTION Inspect the generator set before the first start of the day and after every eight hours of operation Cil Level Check engine oil level p 4 3 Exhaust System Inspect the exhaust system for leaks and loose hose clamps at the exhaust manifold exhaust el bow muffler water separator and hull fittings Re place damaged sections of exhaust hose Check that all CO monitors are working properly EXHAUST GAS IS DEADLY Do not operate the generator set until all exhaust leaks have been repaired Fuel System Check for leaks at hose tube and pipe fittings in the fuel supply and return systems while the generator set is stopped Check flexible fuel hose for cuts cracks abrasions and loose hose clamps Make sure fuel lines do not rub against other parts Re place worn or damaged fuel line parts before leaks occur Replace ho
32. Operator Manual Cummins Onan Performance you rely on Marine Generator Set MDKBK Spec A F MDKBL Spec A F MDKBM Spec A F MDKBN Spec A F MDKBP Spec A E MDKBR Spec A E MDKBV Spec A B MDKBT Spec A B MDKBU Spec A B English Original Instructions 2 2010 981 0181 Issue 4 California Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Table of Contents SECTION PAGE lableoheontenis vig i SAREIMRRECAUTMTION SEPETE SL 6 E iit As AM CENE 1 1 MED a ae 1 1 ARE QOL LED 1 1 HowtotObtaim Service 9 amp A Lc 1 2 Emissions Label T A 1 2 noise ER 1 2 Electromagnetic compatibility 1 3 build Standardsgsgeew 1 4 2 CONIROL PSII 2 1 Remote Control and Monitoring 2 1 oie ooo ooa e 2 1 Cummins Onan Digital Display Panel 2 3 JSOPERATI ON eom qe De M me E DA 3 1 Fuel Hecorsmencallonsue 3 1 Engine Oil Recommendations a a a 3 1
33. abled Output Voltage fell to less than 9096 of rated for 5 seconds Corrective Action 1 Push the generator set line circuit breaker OFF and disconnect the PTO if so equipped If the generator set now runs and voltage and frequency are normal reduce the number of electrical and mechanical PTO loads 2 Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines 3 Check all fuel fittings and filters for fuel and air leaks and tighten as necessary Air bubbles can disrupt generator set frequency voltage 4 Replace fuel filters p 4 6 5 4 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting HIGH AC FREQUENCV CODE NO 14 After the starter was engaged Frequency jumped to more than 70 Hz for 40 milliseconds or to more than 296 over nominal for 6 seconds Corrective Action 1 Check for a tripped generator set circui
34. at least 40 Hz Corrective Action See an authorized Cummins Onan service representative HIGH BATTERY VOLTAGE CODE NO 29 During startup the generator set Controller sensed that battery system voltage was greater than 19 2 volts if 12 VDC system or 32 2 volts if 24 volt system Corrective Action 1 Check battery bank connections and reconnect if necessary for 12 volts or 24 volts depending on generator set model 2 Select a lower battery booster charge rate external charging system STARTING FAULT CODE NO 32 The generator set Controller could not detect cranking speed quadrature zero crossings for 3 sec onds Corrective Action De energize the PTO clutch if so equipped Have the propulsion engines running while trying to start the generator set Their charging alterna tors may be able to maintain a high enough battery terminal voltage to start the generator set Service as necessary by cleaning and tightening battery connections recharging or replacing the battery or replacing damaged battery cables p 4 2 Change the engine oil to oil of the proper viscosity for the ambient temperature High oil viscosity can slow down cranking speed CONTROL CARD FAILURE EE CODE NO 35 During startup the generator set Controller detected a EE memory error Corrective Action See an authorized Cummins Onan service representative 5 6 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set s
35. ce representative FIELD OVERLOAD CODE NO 38 High field voltage induced by high rotor temperature or low power factor loads Corrective Action 1 Remove blockages to generator air flow at the front inlet air grill 2 Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners 3 Have air conditioners and other appliances checked for proper operation A locked compressor rotor can cause very low power factor CONTROL CARD FAILURE RAM CODE NO 43 During startup the generator set Controller detected RAM memory error Corrective Action See an authorized Cummins Onan service representative SPEED SENSE LOST CODE NO 45 After start disconnect the generator set Controller lost speed sense quadrature zero crossings for 0 25 seconds Corrective Action See an authorized Cummins Onan service representative 5 7 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting OVERPRIME
36. ch status lamp will indicate the numeric fault code See Trouble shooting Section 5 STOPPING THE GENERATOR SET Disconnect all electrical loads and disengage the PTO if so equipped to let the generator set run without load and cool down After 2 minutes Push and Release STOP on the Digital Display or control Switch The generator set status lamps will go out After Boil can force large amounts of coolant through the pressure cap and coolant recovery tank Always let the en gine cool down before stopping the generator set Check for loss of coolant after every emer gency stop of fault shutdown Refill and clean up as necessary EMERGENCY STOP Push the EMERGENCY STOP SWITCH to OFF p 2 1 After all necessary repairs have been made push the switch to ON so that the generator set can be operated LOADING THE GENERATOR SET The power rating KW on the generator set name plate determines how much electrical load motors fans pumps heaters air conditioners appliances etc the generator set can power The generator set will shut down or its line circuit breakers will trip if the sum of the concurrent electrical loads exceeds the generator set power rating To avoid shutdowns due to overloading the genera tor set compare the sum of the electrical loads that are likely to be used at the same time to the genera tor set power rating Use the electrical ratings on the nameplates of motors fans pumps and other such
37. d stationary engines and can be found in fuel tanks pipes and injection systems The sub stance should not be used for any other purpose without contacting the manufacturer or supplier In stallers operators and maintainers are likely to en counter this substance HAZARDOUS REACTIONS This liquid is flammable Avoid smoking heat sources such as welding and naked flames sparks and static electricity build up Thermal de composition products are hazardous containing COx NOx and SOx compounds The vapour is explosive High vapour concentra tions 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 oxidising agents e g chlorates which may be use in agriculture Gas oil is slightly irritating to the skin and has a de fatting action Toxicity following single exposure to high level of gas oil is of low order Prolonged re peated skin contact may de fat the skin resulting in possible skin irritation and dermatitis In some cases warty cancerous growths have occurred PROTECTIVE MEASURES Ensure good ventilation and avoid heat sources Observance of good housekeeping rules will en sure 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
38. e emissions regulations is located on the engine as circled in Figure 1 2 Refer also to the FEDERAL EMISSION DESIGN AND DEFECT LIMITED WAR RANTY FOR C I ENGINES DIESELS that was shipped in the same package as the Operator s Manual FIGURE 1 2 TYPICAL EMISSIONS LABEL LOCATIONS NOISE Generator sets emit noise As noise level and time of exposure increase risk of hearing damage in creases The Specifications page in the Operator manual states noise level for this generator set Se lect and use personal hearing protection appropri ate 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 restric tions when you operate the generator set ELECTROMAGNETIC COMPATIBILITY Generator sets emit and receive electromagnetic radio frequency energy If the generator set affects operation of nearby devices or nearby devices af fect generator set operat
39. e form upon inhalation Harmful if swallowed lethal dose for humans re ported to be 100ml PROTECTIVE MEASURES Refrain from eating drinking or smoking when us ing 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 vapour or particulate use a suitable organic vapour mask Eye protection gloves overalls impervious apron should be used Avoid contamination inside the gloves If overalls become contaminated discon tinue use and clean thoroughly STORAGE TRANSPORT Store and transport only in correctly marked con tainers Keep containers closed when not in use Keep cool out of sunlight away for 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 wa ter courses Contain leak spill with sand earth or non combus tible absorbent material to prevent entry of sub stance into drainage 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 and authorised contractor to a licensed site EMERGENCY ACTION e Fire Extinguishing media alcohol resistant foam dry powder or water spray Fire fighters to use self contained breathin
40. egrity or other requirements established by regulatory agen cies such as the US Coast Guard ABYC and ISO When MACHINE CRITICAL parts are re placed for any reason use Onan parts that are identified with the part numbers in the appropri ate Parts Manual 1 1 MODEL IDENTIFICATION Be ready to provide the generator set model and se rial numbers on the nameplate when contacting Cummins Onan for parts service and product infor mation Figure 1 1 illustrates the nameplate and its location on the side of the control box Every charac ter in these numbers is significant The last charac ter of the model number is the specification letter which is important for obtaining the right parts Re cord the generator set model and serial numbers on the lines designated in the figure so that they are easy to find when you need them Improper service or replacement of parts can lead to severe personal injury or death and to damage to equipment and property Ser vice personnel must be qualified to perform electrical and mechanical service IMPORTANT ENGINE INFORMATION A CUMMINS POWER GENERATION 1400 73rd Ave Minneapolis MN 55432 Spec Made USA KVA PH RPM Pf KW 50 Hz 60 Hz As Manufactured Freq AC Volts Amps Fuel Software Cfg Wire Diagram Options
41. eld shall not be run with the service doors removed miss ing e Engine components can be hot and cause se vere burns Hot coolant under pressure can spray and cause severe burns e Use personal protective equipment when maintaining or installing the generator set such as gloves safety glasses etc THE HAZARDS OF CARBON MONOXIDE Engine driven generators can produce harmful levels of carbon monoxide that can injure or kill you The nature of boating is such that you can be harmed by this poisonous gas despite good gener ator set maintenance and proper ventilation ONLY YOU CAN PROTECT YOURSELF FROM CO POISONING e Watch constantly for swimmers when the gen erator set is running e Make sure exhaust cannot get under the deck between hulls or enter the living quarters through a window vent or door e Make sure all CO detectors and audible alarms are working properly e Pay attention to the signs of CO poisoning e Check the exhaust system for corrosion ob struction and leaks each time you start the generator set and every eight hours if you run it continuously SUBSTANCE HAZARDOUS TO HEALTH Generator sets use substances and emit and create wastes that can cause health risks Genera tor set operators must use appropriate personal protective equipment such as clothing gloves protective glasses goggles and respiration equip ment when exposed to fuel oil coolant wet batter ies grease cleaning agents o
42. equipment Refer to Table 3 1 for typical appliance ratings If the equipment is marked in amps and volts only multiply the amps times the volts to obtain the load in watts Divide watts by 1000 to obtain load in terms of kilowatts KW It may be necessary to run fewer electrical loads and appliances at the same time the sum of the loads must not be greater than the generator set power rating The generator set may shut down due to overload ing when a large motor or air conditioner is started or 3 4 cycles off and then on again even though the sum of the electrical loads is less than the generator set power rating The reason for this is that a motor s startup load is much greater than its running load It may be necessary to run fewer electrical loads and appliances when large motors and air con ditioners are cycling on and off On generator sets so equipped the PTO can take most if not all of the power available from the en gine The boat builder may have made provisions to automatically disconnect all or most electrical loads when the PTO is engaged It may be necessary to run fewer electrical loads and appliances or none at all when the PTO is engaged The generator set is rated at standard barometric pressure humidity temperature ref ISO 3046 Either low barometric pressure high al titude or high ambient temperature will decrease engine power It may be necessary to run fewer electrical loads
43. erator 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 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 vii 1 Introduction ABOUT THIS MANUAL This is the Operator Manual for the generator sets li
44. ers viscosity grade Referring to Figure 3 1 choose the viscosity grade appropriate for the ambient temper atures expected until the next scheduled oil change Multi grade oils such as SAE 15W 40 are recom mended for year round use U 32 OF 30 20 10 0 10 20 30 40 50 60 70 80 90 100 110 120 0 OC 34 29 23 18 12 7 4 4 10 16 21 27 32 38 43 48 FIGURE 3 1 OIL VISCOSITY GRADE VS AMBIENT TEMPERATURE ENGINE COOLANT Use the best quality ethylene glycol antifreeze solu tion available It should be fully formulated with rust inhibitors and coolant stabilizers A 50 50 mixture of water and ethylene glycol is recommended to pro vide protection from freezing down to 34 F 37 C Use fresh water that is low in minerals and corrosive chemicals for the coolant mixture Distilled water is best See Specifications Section 6 regarding coolant capacity Ethylene Glycol antifreeze is con sidered toxic Dispose of it according to local regulations for hazardous substances BATTERIES Reliable generator set starting and starter service life depend upon adequate battery system capacity and maintenance See MAINTAINING THE BAT TERY AND BATTERY CONNECTIONS p 4 2 and Specifications Section 6 FIRE EXTINGUISHER PORT The boat must have a fire extinguisher readily avail able for putting out a fire in the genset It must be ap proved for both liquid fuel and electrical equipment A generator se
45. ervice procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting UNKNOWN SHUTDOWN CODE NO 36 The generator set Controller declared this fault because engine speed fell below 1000 RPM for 0 5 sec onds though not by generator set or engine control action Corrective Action 1 Check for mechanical damage and service as necessary 2 Push the generator set line circuit breaker OFF and disconnect the PTO if so equipped If the generator set now runs reduce the number of electrical and mechanical PTO loads Check fuel level and refill as necessary Note The generator set fuel pickups are probably higher than the propulsion engine fuel pickups Prime the engine fuel system for at least 30 seconds p 3 3 Remove combustion air or exhaust system blockages Check all fuel fittings for fuel and air leaks and tighten as necessary Replace fuel filters p 4 6 INVALID GENERATOR SET CONFIGURATION CODE NO 37 The generator set Controller is not configured properly for the generator set Corrective Action See an authorized Cummins Onan servi
46. g apparatus Keep fire exposed containers cool Prevent run off from entering waterways drains and drinking water supplies e Ingestion Toxic by ingestion If swallowed induce vomit ing only under the advice of a Doctor or poison control centre Delayed treatment may result in fatality e Inhalation of vapour Remove from further exposure In case of ir ritation to lungs or throat seek medical advice e Aspiration inhalation of liquid Obtain immediate medical assistance e Eyes Flush copiously with water or preferably eye wash solution for at least five minutes Seek medical advice e Skin Wash thoroughly with soap and water and seek medical attention if irritation develops Change clothing if necessary and wash before re use e Spillage Soak up using an absorbent material and dis pose of this as directed under Storage Trans port GAS OIL This product is also known as Red Diesel Fuel Oil and type A1 or A2 It can be pale red or a clear liquid with a characteristic mild odour It contains catalyti cally cracked oil petroleum distillates quinizarin and gas oil maker dye red The catalytically cracked oil and petroleum distillates are potentially hazard ous constituents The substance has an initial boiling point of 180 C a flash point greater than 56 C and a vapour pres sure 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 ve hicles an
47. ice procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting HIGH ENGINE TEMPERATURE CODE NO 1 Engine coolant temperature exceeds design limit Corrective Action 1 Check for and clean a blocked sea water strainer If above the water line fill the strainer with water to assist priming Check engine coolant level and add coolant as necessary Check for kinked or leaking hoses and reconnect reroute or replace Inspect the siphon break for proper operation p 4 8 Check for a worn raw water impeller and replace as necessary p 4 12 Clean the heat exchanger p 4 8 Check the bottom of the hull for any blockage at the through hull fitting Drain and clean the coolant system to remove coolant passage fouling Page 4 7 LOW OIL PRESSURE CODE NO 2 Low oil pressure Corrective Action Check the engine oil level and add or drain oil as necessary p 4 3 Repair any oil leaks SERVICE CHECK CODE NO 3 A fault with a 2 Digit Fault Code Number occurred Corrective Action Check the 2 Digit fault code by Pushing and Releasing St
48. ifold head and block Follow the manufacturer s instructions for cleaning and flushing Refilling Cooling System Close the block and heat exchanger drain valves and fill the system through the engine fill neck The system will fill only as fast as the air can escape Fill to the bottom of the fill neck Install service doors on generator sets that have a sound shield Start and run the engine for a couple of minutes to dislodge air pockets and shut it down Add as much coolant as necessary and secure the pressure cap Then refill the recovery tank up to the COLD mark Low coolant level can cause severe engine damage Make sure the system is full Heat Exchanger Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Both ends of the heat exchanger Figure 4 4 4 5 or 4 6 have raw water drain plugs and cleanout cov ers If the engine keeps shutting down Code No 1 have a qualified service person clean the raw water tubes Drain the heat exchanger if there is a danger of freezing when the generator set is not running or is in storage Freezing water can damage the raw wa ter tubes in the heat exchanger Engine coolant but not raw water is protected from freezing 4 8 Models MDKBT and MDKBU Do not overtighten the heat exchanger mounting straps or the heat exchanger could be de formed Torque the strap screws as specified in Figure 4 6
49. ing FUEL CONSUMPTION Half Load 0 5 Gal hr 1 9 L hr 0 5 Gal hr 1 9 L hr 0 7 Gal hr 2 5 L hr 7 Gal hr 2 6 L hr Half Load 0 4 Gal hr 1 5 L hr 0 4 Gal hr 1 5 L hr 0 6 Gal hr 2 1 L hr 6 Gal hr 2 2 L hr ENGINE Kubota 4 Stroke Cycle Indirect Injection Water Cooled Diesel with Digital Electronic Governing Md Pme ms vs vs Number of Cylinders 3 09 in 78 4 mm 3 09 in 78 4 mm 3 09 in 78 4 mm 3 09 in 78 4 mm Compression Ratio 241 241 Firing Order Clockwise Rotation 1245 BE Fuel Injection Timing 14 75 16 25 BTDC 14 75 16 25 BTDC 14 25 15 75 BTDC 14 25 15 75 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 L 4 2 quart 4 0 L 4 5 quart 4 3 L 4 5 quart 4 3 L Lube Oil Drain Connection 3 8 NPT 3 8 NPT 3 8 NPT 3 8 NPT Coolant Capacity 4 2 quart 4 0 L 4 2 quart 4 0 L 5 3 quart 5 0 L 5 3 quart 5 0 L Coolant Flow Rate 60 Hz 5 0 Gal min 18 9 L min 5 0 Gal min 18 9 L min 5 0 Gal min 18 9 L min 5 0 Gal min 18 9L min 50 Hz 4 2 Gal min 15 9 L min 4 2 Gal min 15 9 L min 4 2 Gal min 15 9 L min 4 2 Gal min 15 9 L min Raw Water Flow Rate 60 Hz 6 0 Gal min 22 7 L min 6 0 Gal min 22 7 L min 6 0 Gal min 22 7 L min 6 0 Gal min 22 7 L min 50 Hz 5 0 Gal min 18 9 L min 5 0 Gal min 18 9 L min 5 0 Gal min i 18 9 L min 5
50. ion 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 1 3 BUILD STANDARDS The generator sets and its control system have been disigned constructed and tested generally in accor dance with the following Standards where applicable Reference Table 1 1 TABLE 1 1 BUILD STANDARDS BS EN 1037 19954A1 2008 ud of machinery Prevent of unexpected start BS EN ISO 14121 1 2007 Safety of machinery Risk assessment Principles Safety of machinery Safety distance to prevent haz BS EM ard zones being reached by upper and lower limbs 5 j Safety of machinery Minimum gaps to avoid crush BS EN 349 1993 a1 2008 ing parts on the human body Safety of machinery Human body dimensions Part 1 Principles of determining the dimensions re quired for openings for whole body access into ma chinery BS EN 547 1 1996 A1 2008 Safety of machinery Human body dimensions BS EN 547 2 1996 A1 2008 Part 2 Principles for determining the dimensions re quired for access openings Safety of machinery Human body dimensions oL 99090 1 200 Part 3 Anthropomorphic data 3 Safetv of machinerv Electrical equipment of ma 2521 00204 1 2 chines General requirements Safety of machinery Ergonomic design principles BS Terminology and general pri
51. n if symptoms persist Never sleep in the boat when the generator set is running unless the cabin has a working carbon monoxide detector Look over the entire exhaust system and listen for leaks every time you start up the generator set and after every eight hours of operation Shut down the generator set immediately if there is a leak Do not run the generator set until the leak has been repaired The exhaust system must be installed in accordance with the gener ator set Installation Manual Before the first start of the day and after every eight hours of operation inspect the generator set as instructed under GENERAL INSPECTION p 4 2 Keep a log of maintenance and the hours run and perform any maintenance that may be due See Re turning the Generator Set to Service p 3 6 if the boat has been in storage Before each start 1 Make sure all CO detectors on board are work ing properly 2 Check for swimmers that might be exposed to the engine exhaust 3 Disconnect all electrical loads and disengage the PTO if so equipped PRIMING THE FUEL SYSTEM The fuel system should be primed after replacing the fuel filter or running the generator set out of fuel To prime the fuel system Push and Hold STOP on the Digital Display or STOP Prime on the control switch for at least 30 seconds 3 3 STARTING THE GENERATOR SET The generator set can be started and stopped from the generator set control panel or remote control pa
52. n plug or close the oil drain valve Spin off the old oil filter with a filter wrench and wipe off the filter mounting surface Remove the old gasket if it does not come off with the fil ter Apply a film of oil to the new filter gasket and partly fill the new filter with oil so that it reaches engine parts sooner at startup Spin the filter on by hand until the gasket just touches the mount ing pad and tighten 3 4 turn Refill the engine with the proper type and amount of engine oil See ENGINE OIL REC OMMENDATIONS p 3 1 and Specifications Section 6 Check the oil level and add or drain oil as necessary Install service doors on gener ator sets that have a sound sheild Run the gen erator for a few minutes shut it down and re check for proper oil level Dispose of the used oil and oil filter according to local environmental regulations OIL DIPSTICK OIL FILL OIL DRAIN FUEL FILTER AND HOSE WATER SEPARATOR OI FILTER FIGURE 4 1 OIL AND FUEL SERVICE POINTS MDKBK MDKBL MDKBM MDKBN OIL DIPSTICK OIL FILL 9 D cer me
53. nciples Safety of machinery Guards General require BS EN 953 1997 1 2009 ments for the design and construction of fixed and movable guards Safety of machinery Basic concepts general prin Fe ENS ETS qi IL ciples for design Basic terminology methodology Safety of machinery Basic concepts general prin BS EN ISO 12100 2 2008 A1 2009 ciples for design Technical principles Ergonomics of the thermal environment Methods for BS EN ISO 13732 1 2008 the assessment of human responses to contact with surfaces Hot surfaces Safety of machinery Safety related parts of control BS EN ISO 13850 2006 Piu of machinery Emergency stop Principles for Safety of machinery Indication marking and actua BS EN 61310 1 2008 tion Part 1 Requirements for visual auditory and tactile signals 1 4 Safety of machinery Indication marking and actua BIEN 61519 22008 tion Part 2 Requirements for marking Electromagnetic compatibility EMC Generic stan BS EN 61000 6 1 2007 dards Immunity standard for residential commercial and light industrial environments Electromagnetic compatibility EMC Generic stan BS EN 61000 6 3 2007 dards Emission standard for residential commercial and light industrial environments Mechanical vibration and shock Vibration isolation BS EN 1299 1997 A1 2008 of machines Information for the application of source isolation Reciprocating internal combustion engines Saftey
54. nel 1 Visually inspect for water coolant fuel and ex haust leaks Do not start the generator set if there is a leak Repair fuel leaks immediately Push and Hold START on the Digital Display or control switch until the generator set starts The generator set status lamp blinks when the en gine is cranking and comes on and stays on when the generator set starts and runs The status displayed on the Digital Display changes from Starting to Running Figure 2 3 For longer engine life let the engine warm up for two minutes before connecting air condi tioners and other large electrical loads or en gaging the PTO if so equipped Monitor generator set status using the Digital Display p 2 4 if so equipped Perform main tenance or service as necessary if the Digital Display indicates a Pre Alarm condition p 2 3 If the generator set fails to start cranking will discontinue in 20 to 60 seconds depending on engine temperature The Digital Display and or control switch status lamp will indicate Fault Code No 4 See Troubleshooting Section 5 if the generator set does not start after several tries Do not continue cranking and risk burning out the starter or flooding the engine exhaust flow during cranking is too low to expel water from a wet exhaust sys tem Find out why the generator set does not start and make necessary repairs If the generator set shuts down the Digital Display and or control swit
55. ng a sulfur content greater than 10 000 ppm 1 096 weight e Diesel fuel must meet the ASTM D975 stan dard for lubricity and pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0 45 mm as mea sured by ASTM D6079 or ISO 12156 1 e B5 Bio Diesel fuel that meets industry specifi cations and quality is suitable for use with this genset 3 1 ENGINE OIL RECOMMENDATIONS Cil Performance Class Use API American Petroleum Institute classified engine oils according to the following guidelines e Emissions Regulated Areas It is mandatory to use CF CF 4 CG 4 CH 4 or CI 4 class oil with low sulfur fuel sulfur content less than 500 ppm 0 05 weight or ultra low sulfur fuel sul fur content less than 15 ppm 0 0015 weight e Non Regulated Areas CF class oil is recom mended when using high sulfur fuel sulfur content between 500 ppm 0 05 weight and 5000 ppm 0 5 weight If CF 4 CG 4 CH 4 or Cl 4 class oil is used the oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE Page 4 1 e Non Regulated Areas Use CF CF 4 CG 4 CH 4 or Cl 4 class oil when using high sulfur fuel sulfur content between 5000 ppm 0 596 weight and 10 000 ppm 1 096 weight The oil and oil filter must be changed twice as often as specified in the PERIODIC MAINTENANCE SCHEDULE Page 4 1 Cil Viscosity Look for the SAE Society of Automotive Engine
56. ni drame IC 914 Ris IC IC me ner mr c cor c 3ar c PAT OIL DRAIN FUEL FILTER AND HOSE WATER SEPARATOR OI FILTER FIGURE 4 2 OIL AND FUEL SERVICE POINTS MDKBP MDKBR MDKBV 4 4 FUEL FILTER OIL DIPSTICK OIL FILL OIL FILTER OIL DRAIN HOSE FIGURE 4 3 OIL AND FUEL SERVICE POINTS MDKBT MDKBU 4 5 DRAINING REPLACING FUEL FILTERS Diesel fuel is combustible and can cause severe personal injury or death Do not smoke near fuel tanks or fuel burning equip ment 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 fire extinguisher handy Keep dirt water and other contaminants from enter ing the fuel system and corroding or clogging fuel in jection components Draining Water and Sediment The generator set may have a water separator type of fuel filter Fig ure 4 1 4 2 Also check for up stream water sepa rator type fuel filters Drain water and sediment more often than scheduled Table 4 1 if fuel quality is poor or condensation cannot be avoided Dispose of the water sediment and fuel drained off in accor dance with local environmental regulations Replacing Fuel Filters See Table 4 1 for sched uled fuel filter replacement Replace fuel filters Fig ure 4 1 4 2 or 4 3 if
57. nic Governing Md Vm 00 Number of Cyinders Compression Ratio 24 31 Firing Order Clockwise Rotation 1942 Fuel Injection Timing 135 15 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 L 8 quart 7 6 L 8 quart 7 6 L Lube Oil Drain Connection 3 8 NPT 3 8 NPT 3 8 NPT Coolant Capacity 8 quart 7 6 L 8 quart 7 6 L 8 quart 7 6 L Coolant Flow Rate 60 Hz 14 0 Gal min 53 0 L min 14 0 Gal min 53 0 L min 14 0 Gal min 53 0 L min 50 Hz 10 0 Gal min 37 9 L min 10 0 Gal min 37 9 L min 10 0 Gal min 37 9 L min Raw Water Flow Rate 60 Hz 9 0 Gal min 34 1 L min 9 0 Gal min 34 1 L min 9 0 Gal min 34 1 L min 50 Hz 7 0 Gal min 26 5 L min 7 0 Gal min 26 5 L min 7 0 Gal min 26 5 L min Combustion Air Flow 60 Hz 52 ft3 min 1 45 m3 min 60 ft3 min 1 72 m3 min 60 ft3 min 1 72 m3 min 50 Hz 42 ft8 min 1 21 m3 min 50 ft3 min 1 43 m3 min 50 ft3 min 1 43 m3 min Heat Rejection to Ambient 60 Hz 350 Btu min 88 kcal min 420 Btu min 106 kcal min 420 Btu min 106 kcal min 0 Hz 285 Btu min 72 kcal min 350 Btu min 88 kcal min 350 Btu min 88 kcal min Maximum Angularity 10 Continuous 22 5 Intermittent Recommended Fuel No 2 D Diesel Fuel Spec EN 590 or ASTM D975 Ethylene Glycol Spec ASTM D5345 for 50 50 Prediluted Coolant or Recommended Coolant ASTM D4985 for Concentrated
58. o GEN STATUS To calibrate the Digital Display Voltmeter press NEXT on the DISPLAY SETUP screen to select AC Voltmeter Calibration and then press the up or down arrow to increase or decrease the voltage displayed so that it matches that of an accurate AC voltmeter line to line or line to neutral as desired Press BACK to save the selection and get back to GEN STATUS Note This procedure does not change AC output voltage Have a trained and experienced per son adjust AC output voltage if necessary be fore calibrating the Digital Display Voltmeter Generator Set and Display Information Press SETUP on any GEN STATUS screen Press the up or down arrow on the SETUP screen to select GENSET INFO or DISPLAY INFO and press EN TER Figure 2 8 This information may be re quested by the service technician Keep pressing BACK to get back to GEN STATUS From SCREEN Fig 2 3 SCREEN ADJUST Brightness Contrast FIGURE 2 7 SCREEN BRIGHTNESS amp CONTRAST From SETUP Fig 2 3 E SETUP DISPLAY SETUD GENSET INFO DISPLAY INFO DISPLAY SETUP Units AC Volt Meter Calibration 4 NEXT lt Y GENSET INFO GENSET 3261234 V12 34 NIM SW P N 3261234 V12 34 Uc DISPLAY INFO DUBAI EE SW VERSION 12 34 Sup P N 3261234 SF VERSION 10 23 FIGURE 2 8 SETUP GENSET amp DISPLAY INFO 3 Operation FUEL
59. old STOP Prime to prime the fuel system The Amber status lamp lights after 2 seconds and stays on while priming e The Amber status lamp lights during fuel prim ing flashes rapidly during cranking and goes out when the engine is up to speed It also flashes the numeric fault code if the generator set shuts down abnormally See Troubleshoot ing Section 5 e The Green status lamp lights after starting and stays on while the generator set is running Digital Display Panel Optional The local control panel may have a Digital Display panel instead of a control switch See Page 2 3 for instructions on how to use the Digital Display panel Emergency Stop Switch In an emergency push the switch OFF Push it ON after all necessary repairs to the generator set and connected equipment have been made DC Circuit Breaker The circuit breaker protects the DC control circuits of the generator set from short circuits Reset after all necessary repairs have been made to the gener ator set Hour Meter The hour meter records the accumulated number of hours of generator set operating time It cannot be reset OPTIONAL DIGITAL DISPLAY PANEL DIGITAL DISPLAY C CIRCUIT PANEL BREAKER EMERGENCY STOP SWITCH STANDARD CONTROL SWITCH PANEL CONTROL SWITCH WITH STATUS LAMPS EMERGENCY DC CIRCUIT STOP SWITCH BREAKER FIGURE 2 1 GENERATOR SET CONTROL PANEL 2 2 CUMMINS
60. op The 2 Digit fault will be one of the following in this table Does not apply to Digital Display OVERCRANK CODE NO 4 Cranking time exceeded 20 to 60 seconds depending on engine temperature Corrective Action De energize the PTO clutch if so equipped Check fuel level and refill as necessary Note The generator set fuel pickups are probably higher than the propulsion engine fuel pickups Open any closed fuel supply and return valves Prime the engine fuel system for at least 30 seconds p 3 3 Service as necessary by cleaning and tightening battery connections recharging or replacing the battery or replacing damaged battery cables p 4 2 Remove combustion air or exhaust system blockages Check all fuel fittings for fuel and air leaks and tighten as necessary Replace fuel filters p 4 6 Check for contaminated fuel by connecting to a source of known fuel quality Change the engine oil to oil of the proper viscosity for the ambient temperature High oil viscosity can slow down cranking speed 5 3 TABLE 5 1 TROUBLESHOOTING GENERATOR SET FAULTS CONT Some generator set service procedures present hazards that can result in severe per sonal injury or death Only trained and experienced service personnel with knowledge of fuels elec tricity and machinery hazards should perform generator set service See Safety Precautions Accidental or remote starting can cause severe personal injury
61. or death Before removing a panel or access door disconnect the negative cable from the battery to prevent the engine from starting WARNING SHUTDOWN DUE TO VESSEL CO CODE NO 5 Dangerous levels of Carbon Monoxide in Vessel Corrective Action Get everyone out into fresh air immediately and seek medical attention LOSS OF RAW WATER FLOW CODE NO 7 Low raw water pressure in heat exchanger Corrective Action 1 Open the sea cock 2 Check for a blocked sea water strainer and clean it out If above the water line fill the strainer with water to assist priming 3 Check for kinked or leaking hoses and reconnect reroute or replace 4 Check for a worn raw water impeller and replace as necessary p 4 12 5 Check the bottom of the hull for any blockage at the through hull fitting HIGH AC VOLTAGE CODE NO 12 After voltage regulation was enabled Output Voltage jumped to more than 12596 of rated for 75 millisec onds or to more than 11596 of rated for 3 seconds Corrective Action 1 Check for a tripped generator set circuit breaker reset if necessary and run with fewer loads breaker tripping under load can cause generator set voltage to overshoot 2 Check all fuel fittings and filters for fuel and air leaks and tighten as necessary Air bubbles can disrupt generator set frequency voltage 3 Prime the engine fuel system for at least 30 seconds p 3 3 LOW AC VOLTAGE CODE NO 13 After voltage regulation was en
62. 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 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 laun dered before re use No special respiratory precautions are necessary in normal use DO NOT use as a solvent for removing dirt grease etc from skin STORAGE TRANSPORT Store and transport only in correctly marked con tainers 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 trans fer Contain leak spill with sand earth or other suitable material and prevent entry of substance into drain age sewerage system water courses and land Dispose of unwanted or absorbed substance through an authorised contractor to a licensed site Inform local and fire authorities should the product reach waterways drains etc EMERGENCY ACTION e Fire Extinguishing media Large fire Foam water fog Never use water jet Small fire foam dry powder AAAF CO sand earth Avoid making sparks Fire fighters to use self contained
63. r connecting shore power the boat must have an approved de vice to keep the generator set and shore power from being interconnected 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 in terconnections 3 5 LINE CIRCUIT BREAKER HANDLES PULL FORWARD FOR ON FIGURE 3 3 TYPICAL LINE CIRCUIT BREAKERS COLD TEMPERATURE OPERATION Drain the heat exchanger p 4 8 and muffler be fore cold weather sets in if the generator set is not being used Freezing water can damage the muffler and the raw water tubes in the heat exchanger CARE OF NEW OR RE BUILT ENGINE Avoid no load operation as much as possible during break in Change the oil and oil filter after the first 50 hours of operation p 4 3 EXERCISING THE GENERATOR SET Exercise the generator set at least 1 hour every month if use is infrequent Run the generator set at 1 4 to 3 4 load A single exercise period is better than several shorter periods Exercising a generator set drives off moisture re lubricates the engine uses up fuel before it becomes stale and removes oxides from electrical contacts The result is better starting more reliable operation and longer engine life STORING THE GENERATOR SET Proper storage is essential for preserving top gener a
64. r or wet exhaust Cooler keel cooler when provided is part of the pressurized closed loop liquid cooling sys tem through which the coolant flows Heat Exchanger When a heat exchanger is pro vided raw water the floatation water is pumped through tubes in the heat exchanger to cool the en gine coolant The water is then passed through a hose into the exhaust water mixer to cool the ex haust gases The raw water is expelled from the boat along with the exhaust gases Recommended Coolant Mixture See ENGINE COOLANT p 3 2 for recommenda tions Replenishing Normal Coolant Loss Check coolant level in the recovery tank before the first startup of each day and if necessary refill to COLD when the engine is cold or to HOT when it is running The recovery tank is designed to maintain coolant level not to fill the system If the tank is empty check for and repair any coolant leaks and refill the system through the fill neck on the engine Pressure Cap Let the engine cool down before removing the coolant pressure cap or opening the coolant drain Hot coolant under pressure can spray and cause servere burns Wear safety glasses Replace the pressure cap every two years seals deteriorate and leak Proper cooling system pres sure 7 psi is essential for optimal engine cooling and minimal coolant loss 4 7 Coolant Hoses Engine components drains filters hoses etc will be hot and can cause severe b
65. r other substances exposed to lungs eyes or skin Use appropriate containers for transport storage and disposal of waste substances Follow local regulations for dis posal and recycling ANTIFREEZE FLEETGUARD ES COMPLEAT EG PREMIX This antifreeze is also know as an ethylene glycol based coolant summer coolant coolant additive It is purple coloured viscous liquid with a mild chemi cal odour is soluble in water and harmful It con tains ethylene glycol and diethylene glycol Ethyl ene 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 ex changers Installers operators and maintainers are likely to encounter this substance HAZARDOUS REACTIONS Ethylene glycol is combustible when exposed to heat or flame and can react vigorously with oxi dants Moderate explosive hazard in form of vapour when exposed to heat or flame Hazardous prod ucts resulting from combustion 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 particulat
66. result in severe per sonal injury or death ENGINE EXHAUST IS DEADLY e Never sleep in the boat while the generator set is running unless the boat is equipped with properly working carbon monoxide detectors e The exhaust system must be installed in accor dance with the generator set Installation Manual and be free of leaks e Make sure the bilge is adequately ventilated with a power exhauster e Inspect for exhaust leaks every startup and af ter every eight hours of operation e For more information about carbon monoxide see American Boat and Yacht Council ABYC publication TH 22 Educational Information About Carbon Monoxide GENERATOR VOLTAGE IS DEADLY e Generator electrical output connections must be made by a trained and experienced electri cian in accordance with applicable codes 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 e Use caution when working on live electrical equipment Remove jewelry make sure cloth ing and shoes are dry stand on a dry wooden platform or rubber insulating mat and use tools with insulated handles DIESEL FUEL IS COMBUSTIBLE e Do not smoke or turn electrical switches ON or OFF where fuel fumes are present or in areas sharing ventilation with fuel tanks or equip ment Keep flames sparks pilot lights arc producing equipment and all
67. se with a USCG TYPE A1 or ISO 7840 A1 fuel hose Prime the fuel system if the generator set ran out of fuel Fuel leaks can lead to fire Repair leaks immediately Do not run the generator set if it causes fuel to leak Coolant Level Check coolant level in the recovery tank and if nec essary refill the recovery tank to COLD when the engine is cold or to HOT when it is at normal running temperature The recovery tank is designed to maintain coolant level not to fill the system If the tank is empty check for and repair any coolant leaks and refill the system through the fill neck on the en gine See Refilling the Cooling System p 4 8 Use the recommended antifreeze mixture p 3 2 Raw Water System Clean out the sea water strainer if necessary and make sure the sea valve is open for generator set 4 2 operation Also when a water exhaust separator is provided open the sea valve for the water drain hose Check for hoses that leak or are damaged Have a qualified service person replace any leaking or damaged hoses Mechanical Monitor generator set status using the Digital Dis play p 2 4 Visually inspect genset for mechanical damage For generator sets with a sound shield install service doors before running the generator set to listen for unusual noises Check the generator set mounting bolts Check to see that the generator set air inlet and outlet openings are not clogged with debris or blocked Keep
68. sted on the front cover Each operator should study this manual carefully and observe all of its instruc tions and safety precautions Keep this manual close at hand for reference This generator set is not a life sup port system It can stop without warning Chil dren persons with physical or mental limita tions and pets could suffer personal injury or death A personal attendant redundant power or alarm system must be used if generator set operation is critical This generator set is not ignition protected and shall not be used in flammable vapor environment This generator set shall not be the main source of power for communication and steering systems It can stop without warning Operation Periodic Maintenance and Trouble shooting provide the instructions necessary for op erating the generator set and maintaining it at top performance The owner is responsible for perform ing maintenance in accordance with the PERIODIC MAINTENANCE SCHEDULE p 4 1 This manual also includes generator set specifications informa tion on how to obtain service and information re garding compliance with emissions regulations See the Parts Manual for part identification numbers and required quantities Genuine Cummins Onan replacement parts are recommended for best re sults Within the Parts Manual MC parts are MACHINE CRITICAL and must comply with boating safety ignition protection backfire fire resistance exhaust system int
69. t breaker reset if necessary and run with fewer loads breaker tripping under load can cause generator set frequency to overshoot 2 Check all fuel fittings and filters for fuel and air leaks and tighten as necessary Air bubbles can disrupt frequency LOW AC FREQUENCV CODE NO 15 During normal operation Frequency fell to less than 9096 of nominal for more than 8 seconds Corrective Action 1 Push the generator set line circuit breaker OFF and de energize the PTO clutch if so equipped If the generator set now runs reduce the number of electrical and mechanical PTO loads especially those with high motor starting loads such as air conditioners Check the fuel tank and fill as necessary Note The arrangement of pickup tubes in the fuel supply tank probably is such that the generator set will run out of fuel before the propulsion engines Prime the engine fuel system for at least 30 seconds p 3 3 Remove combustion air or exhaust system blockages Check all fuel fittings for fuel and air leaks and tighten as necessary Air bubbles can disrupt fre quency Replace fuel filters p 4 6 Check for contaminated fuel by connecting to a source of known fuel quality GOVERNOR OVERLOAD CODE NO 22 Maximum allowable time at full duty cycle was exceeded Corrective Action Reduce the number of appliances running at the same time especially those with high motor starting loads such as air conditioners
70. t with an enclosure has a fire extin guisher port accessible by breaking through the circle on the warning label located as shown in Fig ure 3 2 Make sure that the nozzle of the fire extinguisher that will be used in the event of fire is smaller than the circle so that it will fit through the port The fire extinguisher must be of the gaseous type In the event of fire 1 DO NOT open the generator set enclosure 2 Shut down engines generators and blowers 3 Break through the circle on the label with the nozzle and discharge the full contents of the fire extinguisher 3 2 A WARNING In case of fire do not open soundshield Avoid serious injury or death from fire Shut down engines generator sets and blowers Immediately discharge entire contents of gaseous portable fire extinguisher through this port Break Thru Here Extinguisher Port 98 7472 FIGURE 3 2 FIRE EXTINGUISHER PORT PRE START CHECKS EXHAUST GAS is deadly All en gine exhaust contains carbon monoxide an odorless colorless poisonous gas that can cause unconsciousness and death Symptoms of carbon monoxide poisoning include e Dizziness e Headache e Nausea e Weakness and Sleepiness e Vomiting e Inability to Think Coherently GET EVERYONE OUT INTO FRESH AIR IMMEDI ATELY IF ANYONE EXPERIENCES ANY OF THESE SYMPTOMS Seek medical attentio
71. the engine lacks power 4 6 1 Disconnect the negative cable at the battery to prevent the engine from starting and close any fuel supply and return valves Accidental or remote starting can cause severe personal injury or death Disconnect the negative cable at the bat tery to prevent the engine from starting Engine components drains fil ters hoses etc will be hot and can cause severe burns The use of protective gloves is recommended Spin off the old filter with a filter wrench and dis pose of it in accordance with local environmen tal regulations Clean the contact surface on the filter base lu bricate the new filter gasket and spin the new filter on hand tight Prime the engine for at least 30 seconds p 3 3 to fill the new filter Install service doors on generator sets that have a sound shield Run the generator for a few minutes shut it down and check for leaks Tighten the filter by hand if necessary MAINTAINING THE ENGINE COOLING SYSTEM Refer to Table 4 1 for scheduled maintenance 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 ex haust manifold Figure 4 4 4 5or 4 6 Heat is car ried away from the coolant by a keel cooler or raw water sea water heat exchanger A gear driven raw water pump is provided if the generator set has a heat exchange
72. the generator set compartment clean MAINTAINING THE BATTERY AND BATTERY CONNECTIONS Arcing at battery terminals or in light switches or other equipment and flames or sparks can ignite battery gas causing severe personal injury Ventilate battery area before working on or near battery Wear safety glasses Do not smoke Switch work light ON or OFF away from battery Stop generator set and disconnect charger before disconnecting battery cables Disconnect negative cable first and reconnect last Refer to Table 4 1 for scheduled battery mainte nance and follow the battery manufacturer s in structions Have the battery charging system ser viced if DC system voltage is consistently low or high Check the battery terminals for clean tight connec tions Loose or corroded connections have high electrical resistance which makes starting harder Always 1 Keep the battery case and terminals clean and dry and the terminals tight 2 Remove battery cables with a battery terminal puller Make sure which terminal is positive and which is negative before making battery connections always removing the negative cable first and reconnecting it last to reduce arcing CHECKING ENGINE OIL LEVEL State and federal agencies have de termined that contact with used engine oil can cause cancer or reproductive toxicity Avoid skin contact and breathing of vapors Use rub ber gloves and wash exposed skin
73. tor set performance and reliability when the gener ator set cannot be exercised regularly and will be idle for more than 120 days Storing the Generator Set 1 Turn off the generator set line circuit breaker 2 Change the engine oil and filter and attach a tag indicating oil viscosity See ENGINE OIL REC OMMENDATIONS p 3 1 3 Crank the engine several revolutions but do not let it start This will fill the oil passages with the new oil 3 6 Disconnect the battery cables negative cable first from the starting battery and store the battery according to the battery manufac turer s recommendations See MAINTAINING THE BATTERY AND BATTERY CONNEC TIONS p 4 2 Check coolant level and add as necessary p 4 7 Test the coolant mixture if freezing temperatures are possible and change if nec essary Hot coolant is under pressure and can cause severe burns when loosen ing the pressure cap Let the engine cool before loosening the pressure cap 6 Drain the heat exchanger and muffler if freezing temperatures are expected 7 Disengage a PTO clutch if so equipped 8 Clean and lightly oil parts that can rust Returning the Generator Set to Service 1 Check the oil tag on the generator set and change the oil if the viscosity indicated is not appropriate for the temperatures expected See ENGINE OIL RECOMMENDATIONS p 3 1 2 Reconnect the starting battery negative cable last See MAINTAINING THE B
74. unning them out of fuel Break Out Tool 420 0624 Break out tool 420 0624 for use in conjunction with an accurate digital multi meter is available for pre forming stator winding output tests while running the generator set The tool is plugged into the generator set wiring harness in place of the generator set con trol Follow the tool instructions TROUBLESHOOTING WITH DIGITAL DISPLAY If fault shutdown occurs the ALARM status lamp on the Digital Display will blink and the LCD screen will display the Fault Number a description of the Fault and the hour in total generator set running time when the Fault occurred Figure 2 4 The fault will be displayed until it is cleared Touch any button to clear the fault The display will turn off in 5 minutes after the fault has been cleared See Page 2 6 to display any of the last five faults in fault history 5 1 TROUBLESHOOTING WITH STATUS LAMP If a fault shutdown occurs the amber status lamp on the control switch will repeatedly blink sets of 3 4 5 or 7 blinks e One blink indicates shutdown due to high en gine temperature e Two blinks indicate shutdown due to low oil pressure e Three blinks indicate a service fault Press Stop once to cause the two digit shutdown code to blink Pressing Stop again will stop the blinking The two digit code consists of 1 to 7 blinks a brief pause and then 1 to 9 blinks The first set of blinks represents the tens digit and the
75. urns The use of protective gloves is recom mended Check for hoses that leak or are damaged Have a qualified service person replace and leaking or damaged hoses Draining and Cleaning Cooling System Have towels and containers ready to wipe up col lect and properly dispose of the coolant Disconnect the negative cable at the battery to prevent the engine from starting and let the engine cool before removing the pressure cap Accidental or remote starting can cause severe personal injury or death Discon nect the negative cable from the battery to prevent the engine from starting Let the engine cool down before removing the coolant pressure cap or open ing the coolant drain Hot coolant under pressure can spray and cause servere burns Wear safety glasses Engine components drains filters hoses etc will be hot and can cause severe burns The use of protective gloves is recom mended Remove the pressure cap and open the block and heat exchanger drain valves Figure 4 4 4 5or 4 6 and drain the coolant into suitable containers for dis posal in accordance with the local regulations for hazardous substances Drain or flush a keel cooler in accordance with the manufacturer s instructions Use radiator cleaning chemicals to clean and flush the cooling system before refilling with fresh cool ant Follow the cleaner manufacturer s instructions Filling a hot engine with cold water can cause cracks in the man

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