cummins panels

00-02-0442 Revised 11/05

Subject:

Instructions for Premium

Instrument Panels

This AEB is for the following applications:

• Automotive • Industrial • G-Drive [X] Marine

Date Created: 05/03/2003

Revision Date: 11/09/2005

Expire Date: 11/09/2006

File Name : 0.15.00

Controls, Gauges &

Alarms

MAB No.

0.15.00-05/03/2003

Engine Family : All

Engine Model : All

Author : John Yancone of 30

Purpose

This Bulletin defines requirements for mounting, installing, adjusting and testing of instrument panels for the engine-room and/or pilot-house. These procedures and requirements apply to the instrument panels used on all electronic and mechanical, N, K & QSK engine series marine applications.

Introduction

The Premium Panel Series is a family of instrument panel and wiring harness options available for Cummins Marine Heavy Duty and High Horsepower engines. The option series includes many common components with minor design differences between panel sets for mechanically controlled and electronically controlled (CENTRY or Quantum) engines.

Cummins Confidential

SECTION PAGE Summary - Installation Requirements 2 Discussion - Instrument Panel Features 3 Panel Mounting Instructions 4 Wiring Harness Installation 5

Engine Room Harnesses 6 Pilot House Extension Harness 7

Engine Room Panel - Functions; Connections CO

Tachometer / Hour Meter 9 Engine Oil Pressure Gauge & Alarm 10 Marine Gear Oil Pressure Gauge & Alarm 11 Engine Speed Switch 12 Crankcase Pressure Gauge 12 Engine Coolant Temperature Gauge & Alarm 13 Exhaust Temperature Pyrometer 13

Pilot House Panel - Functions and Connections 14 Alarm Annunciator 14 Tachometer 15 Engine Coolant Temperature Gauge 15 Engine Coolant Level Gauge & Alarm 15

Engine Room Panel - Calibrations & Adjustments 17 Pilot House panel - Calibrations & Adjustments 20 Alarm System Tests 21

Summary of Installation Requirements

• Use of the Engine Room Panel without the Pilot House Panel requires installation of a remote start/stop switch, a low oil pressure alarm, and a high coolant temperature alarm.

• The Engine Room Panel must be remotely mounted, off engine, in a dry location not exposed to large amounts of water and must not be mounted directly above the engine.

• The Engine Room Panel must be located near the engine within the 25 ft. reach of the coolant temperature sensor capillary tube.

• The Engine Room Panel must be mounted using rubber isolators (supplied in kit) to minimize vibration.

• The Pilot House Panel must be installed only in combination with the Engine Room Panel. It is driven by electrical senders included in the Engine Room Panel and will not operate properly without the Engine Room Panel.

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• Wiring harnesses must be located where the harness will not be subjected to physical damage or high temperatures and will not interfere with normal engine room or pilot house activities. Harnesses must be supported in a cable race or by a continuous series of cable clips spaced at no more than 300 mm (12 in.) apart and must not be subjected to excessive tension.

• If the total length of the extension harness to the Pilot House Panel exceeds 150 f t , voltage at the Pilot House Panel must be measured to assure a minimum of 10.0 Volts (20.0 Volts for 24 volt systems) to assure proper operation of gauges, alarms and controls.

• For CENTRY engines the Datalink Connector must be accessible for connection to Cummins INSITE and E-Check diagnostic service instruments.

• The Speed Sensor lock nut must not be over torqued. Do not exceed 27 - 34 N-m (25 - 35 ft-lb). Over torquing can damage the sensor.

• Customer add-on devices that use the Engine Speed Sensor signal must not degrade signal voltage. Signal voltage at both tachometers (engine room and pilot house) and the speed switch must be greater than 6.0 volts, peak-to-peak, measured with all add-on devices operating and engine speed at low-idle.

• Hoses must be routed where they will not be subjected to physical damage or high temperatures and will not interfere with normal engine room activities.

• The oil pressure pulsation damper supplied with the panel must be installed at the marine gear oil pressure connection. Failure to install the pulsation damper will result in damage to the pressure sender.

• The crankcase pressure connection hose must be routed with a continuous upward slope from the engine toward the instrument panel with no dips where oil may collect.

• The coolant temperature sensor capillary tube must not be sharply kinked or crushed and must not be cut. Any excess length must be smoothly coiled and secured in an area where it will not be damaged.

• The panel alarm system must be fully adjusted and tested before or during sea-trials.

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Discussion

Instrument Panel Features

This section includes a description of panel features, installation instructions for panels and wiring harnesses and calibration and adjustment procedures instruments and alarms. Functional testing of alarms is also included.

Engine Room Panel Features

GAUGES • Analog Tachometer and Digital Hour Meter. • Engine Oil Pressure - Mechanical, with dual alarm switches. • Engine Coolant Temperature - Mechanical, with alarm switch,

Capillary Tube, Temperature Sensing Bulb. • Gear Oil Pressure - Mechanical, with alarm switch. • Crankcase Pressure - Mechanical, with alarm switch. • Voltmeter. • Pyrometer - Single or Dual.

CONTROLS AND ALARMS • Toggle Switch for Local / Remote Control Function. • Push-Button Engine-Start Switch. • Push-Button Engine-Stop Switch. • Circuit Breaker Reset Button. • System Power Indicator Light. • Warning Light

LOOSE KITTED PARTS • Pulsation damper • Thermocouple(s) - Type K (Chromel-Alumel)-Grounded • Thermocouple Mounting Adapter(s) - ¼ NPT. • Mounting Vibration Isolators • Engine Speed Sensor

Pilot House Panel Features

GAUGES • Digital Tachometer. • Engine Oil Pressure. • Gear Oil Pressure. • Engine Coolant Temperature.

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CONTROLS AND ALARMS • Key Switch For Engine Start. • Push-Button Engine-Stop Switch. • Engine Warning Light - Not active on Mechanical engines. • Annunciator Panel - Alarm Silence/Test Button, Warning lights and

Alarm Horn for: Low Engine Oil-Pressure, Low Gear Oil-Pressure, Low Engine Coolant Level, High Engine Coolant Temperature, High Crankcase-Pressure, Spare Alarm.

• Power-On indicator light. • Dimmer Switch For Panel Lighting. • QSK Series Unique Features • Analog or Digital Tachometer Optional. • Data Link Connector (for engine diagnostic tool). • Increment / Decrement Switch (for engine diagnostics). • Diagnostic Switch. • Engine Control System Fault Indicator Lights: Stop, Warning, Fluid.

LOOSE KITTED PARTS • Coolant Level Sensor/Switch. • Temperature Sender. • Temperature Sender Boot. • Temperature Sender Adapter 3/4-16.

CAUTION!

Before Beginning Installation:

1. Disconnect all electrical power to the engine. Make sure the engine cannot be started during installation.

Panel Mounting Instructions

Engine Room Panel

• Use of the Engine Room Panel without the Pilot House Panel requires installation of a remote start/stop switch, a low oil pressure alarm, and a high coolant temperature alarm.

• The Engine Room Panel must be remotely mounted, off engine, in a dry location not exposed to large amounts of water and must not be mounted directly above the engine.

• The Engine Room Panel must be located near the engine within the 25 ft. reach of the coolant temperature sensor capillary tube.

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• The Engine Room Panel must be mounted using rubber isolators (supplied in kit) to minimize vibration.

The Engine Room Panel may be installed independently or in combination with the Pilot House Panel. Combined installation is preferable to attain full use of all alarms and gauges. Installations using only the engine room panel must include the following (not supplied):

1. A start/stop switch must be installed in the main pilot house to allow the operator to remotely shut off the engine. For all engines except QSK19-M, the switch should be installed across the fuel shut-off valve (FSOV) and key switch circuits (pins C and D at the connector for the remote extension harness). QSK19-M engines require the switch installation across the battery power and key switch circuits (pins B and D at the connector for the remote extension harness). Refer to the appropriate wiring diagram for more detail.

2. Alarms must be installed (in the pilot house) to warn the operator of low oil pressure and high coolant temperature. The alarms may be driven either by the switch gauges (which can output a maximum of two amps at rated voltage), in the engine room panel or by external alarm switches.

The engine room panel should be mounted so that is easily accessible by an operator and such that the engine can be observed during start-up and shutdown. Typical panel mounting locations include attachment to overhead structure, bulkheads, or foundation posts. Panels may be surface mounted from the sides, or mounted with a fabricated angle bracket (not supplied). Four mounting holes are located on the sides of the panel box.

Pilot House Panel

• The Pilot House Panel must be installed only in combination with the Engine Room Panel. It is driven by electrical senders included in the Engine Room Panel and will not operate properly without the Engine Room Panel.

The Pilot House Panel should be located such that all gauges and controls are visible from the operator's position, and should be shaded from direct sunlight to minimize reflections and glare from the face of the panel.

The panel may be flush mounted with or without the bezel frame provided. It requires a cutout and clearance for the bezel (if used) of the dimensions shown in Figure 1, and must be secured with 4 suitable fasteners (Not Supplied).

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FIGURE 1

NOTE: Calibration of the Pilot House Panel tachometer requires access to the back of the panel. Final installation of the panel should be delayed until calibration is complete unless access can be maintained.

Wiring Harness Installation

• Wiring harnesses must be located where the harness will not be subjected to physical damage or high temperatures and will not interfere with normal engine room or pilot house activities. Harnesses must be supported in a cable race or by a continuous series of cable clips spaced at no more than 300 mm (12 in.) apart and must not be subjected to excessive tension.

Electrical connections for the instrument panel controls and gauges are made through a series of wiring harnesses. Figures 2 & 3, show a typical arrangement of harness connections used to complete connections with the Engine Room Panel and the Pilot House Panel. Installation of the harnesses requires routing the harness through the vessel from the engine to the panel locations and making the necessary connections at terminals and connectors.

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Consult the appropriate Wiring Diagram for wiring harness details and options.

FIGURE 2

ENGINE HARNESS

MARINE OEM ENGINE HARNESS

ENGINE ROOM EXTENSION HARNESS

ENGINE ROOM PANEL

FIGURE 3

ENG.ROOM EXTENSION HARNESS ENGINE ROOM

PANEL PILOT HOUSE EXTENSION HARNESS

PILOT HOUSE PANEL

Engine Harness

The Engine Harness comes factory installed on the engine and includes Deutsch connector(s) for attachment of the Marine OEM Engine Harness. Figure 4 shows typical connectors on the engine.

FIGURE 4

CONNECTORS FOR MARINE OEM ENGINE HARNESS

(TYPICAL) QSK19 SHOWN

Marine OEM Engine Harness

The Marine OEM Engine Harness provides the interface with the engine harness and also contains additional terminals/connectors for connection to specific sensors and controls for the instrument panel(s).

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1. Connect all harness leads to sensor terminals and connectors.

2. Determine the optimum harness attachment points and connector location on the engine.

3. Secure the Marine OEM Engine Harness in place on the engine using brackets, clips and wire-ties provided. For K19 and K-Vee applications connector brackets are not provided with the harness and must be fabricated. The brackets should be attached to the engine and must support the connectors to prevent chafing and vibration damage.

Engine Room Extension Harness

Connection to the Engine Room Panel is completed by connecting the Engine Room Extension Harness to the OEM harness and to the instrument panel as shown in Figure 5.

1. Engine room extension harnesses are available in 15 and 30 foot lengths. Refer to the appropriate Wiring Diagram for Option Numbers.

2. Determine the optimum harness routing to the panel, and secure in place using appropriate supports (Not Supplied).

3. Connect the Deutsch connectors to the Marine OEM Engine Harness and to the panel.

FIGURE 5

Pilot House Extension Harness

• If the total length of the extension harness to the Pilot House Panel exceeds 150 ft., voltage at the Pilot House Panel must be measured to assure a minimum of 10,0 Volts (20.0 Volts for 24 volt systems) to assure proper operation of gauges, alarms and controls.

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• For CENTRY engines the Datalink Connector must be accessible for connection to Cummins INSITE and E-Check diagnostic service instruments.

Connection to the Pilot House Panel is completed by connecting the Pilot House Extension Harness to the between the Engine Room and Pilot House Panels as shown in Figure 3 above.

The Pilot House Extension Harness provides all connections for gauges and controls on the Pilot House Panel and includes the Data Link Connector (for CENTRY Engine applications). The harness provides Deutsch connector(s) to the Engine Room Panel and flying leads for connection to the terminal strip at the back of the Pilot House Panel, Figure 6. In general, it will be necessary to cut the Pilot House Extension Harness to length and prepare the leads for connection to the terminal strip as described below.

Figure 6 Figure 7

1. Pilot-house panel extension harnesses are available in 50, 100, and 150 foot lengths. Refer to the appropriate Wiring Diagram for Option Numbers.

2. Determine the optimum routing for the extension harness and route the harness from the Engine Room Panel to the Pilot House Panel terminal strip.

3. Select the required length of harness. Consider the need to strip insulation and tin (solder) the wire ends for attachment to the panel terminal strip in selecting the length of the harness.

4. At the Pilot House Panel end, trim the harness to the desired length. Be sure to allow sufficient length to strip insulation, tin (solder) the leads and connect to the panel terminal strip. Do not cut the harness at the Deutsch connector end.

5. Prepare the trimmed wire ends and referring to the appropriate Wiring Diagram connect them to the terminal strip on the back of the panel.

• For ease of installation the terminal strip may be temporarily loosened from the panel as shown in Figure 7 above. To loosen the terminal strip, remove the hex nuts at either end of the strip. Some wire-ties

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may need to be cut to free up the terminal strip. Be sure to retie these when the terminal strip is replaced. If panel wires are disconnected for easier access be sure to note their positions for correct reconnection.

• For ease of identification it is recommended that each wire be labeled with the corresponding wire number as given in the appropriate Wiring Diagram. Figure 8 shows the terminal strip with labeled wires attached.

• Strip 10 mm (3/8") of insulation from the wire ends and tin the exposed wire tip with solder appropriate for electrical applications.

• Insert each wire tip into the corresponding cavity as indicated in the appropriate Wiring Diagram, and tighten the locking screws to 0.68 NM [5 lb-in]. Wire ends and terminal strip wire cavities are labeled as shown on the Wiring Diagram.

• After all wires are securely attached to the terminal strip re-attach the strip to the panel. Torque the attaching hex nuts to 1.4 NM [10 lb-in]. Do not over-tighten.

6. For CENTRY engines only, attach the DataLink connector using butt splices. Refer to the appropriate Wiring Diagram for correct + / - polarity.

FIGURE 8

Engine Room Panel - Functions; Connections:

This section describes the functions and connection requirements for each of the Engine Room Panel gauges. Adjustment and testing of all gauge alarms and other calibrations requiring power-on and/or engine running will be performed after panel installation is complete.

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Tachometer / Hour-meter

The engine room tachometer has an analog (dial-type) RPM indicator and a digital Hour-Meter. Electrical engine- speed signals are generated by the speed-sensor which must be installed on the flywheel housing and connected to the Marine OEM Engine Harness.

Speed Sensor Signal

The engine Speed Sensor is a magnetic pickup that "detects" the flywheel ring-gear teeth when the engine is running. The gear teeth passing the pickup generate an alternating-current electrical signal. Peak to peak voltage of the signal may vary from 6.0 volts to 85.0 volts depending on gear tooth configuration, relative surface speed of the gear teeth (engine speed) and gap clearance to the Speed Sensor.

Speed Sensor Installation

• The Speed Sensor lock nut must not be over torqued. Do not exceed 27 - 34 N-m (25 - 35 ft-lb). Over torquing can damage the sensor.

1. The Speed Sensor is installed on the engine flywheel housing. Refer to the appropriate Installation Diagram to locate the proper port on the flywheel housing to install the Sensor.

2. Remove the plug from the flywheel housing port (if required) and bar the engine over to visually align the center of a ring-gear tooth with the center of the hole.

3. Insert the Speed Sensor and turn it down (clockwise), by hand, until the sensor just touches the top of the ring-gear tooth. Then, turn the sensor out (counter-clockwise) 1/ 2 turn for the proper clearance.

4. Tighten the lock nut against the flywheel housing to 34 to 27 N-m (25 to 35 ft-lb). Do not allow the sensor to turn while tightening the lock nut.

5. Connect the leads from the Speed Sensor to the connector provided in the Marine OEM Harness.

Customer Add-On Devices Reguiring Speed Sensor Signal

• Customer add-on devices using the Engine Speed Sensor signal must not degrade signal voltage. Signal voltage at both tachometers (engine room and pilot house) and the speed switch must be greater than 6.0 volts, peak-to-peak, measured with all add-on devices operating and engine running at low-idle.

The Speed Sensor is designed to provide the speed signal to the instrument panel tachometers and speed switch. Other devices requiring an engine speed signal may be connected to the sensor output, but caution must be exercised to

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assure that the additional electrical load does not degrade the signal. A degraded or altered signal may cause unacceptable performance of the tachometers or speed switch.

The Speed Sensor signal may be accessed in the Engine Room Panel or the Pilot House Panel. Do not attempt to splice into the wiring harness.

1. If making connections at the Engine Room Panel route the leads from the add-on device into the panel box through the rubber grommet at the capillary tube opening. If connecting at the Pilot House Panel access the back of the panel.

2. Locate the "Signal" and "Ground" terminals on the back of the tachometer (Refer to the Wiring Diagram.), and attach the leads from the add on device to the terminals. Be sure all leads are securely reattached. Note: The steel frame of the panel is electrically isolated from all circuitry. It is not connected to common ground and does not provide a ground connection point.

Engine Oil-Pressure Gauge & Alarm

The engine oil pressure gauge indicates engine oil-pressure and also provides two alarm modes to warn the operator of low oil pressure conditions.

Operating modes and warning states of the two alarms are shown in Table 1.

TABLE 1: Engine Oil Pressure Alarm Modes

ALARM MODE

CONDITION MONITORED

ALARM ENABLED

ALARM DISABLED

ALARM SET POINT

1st Mode Normal

Engine Speed Operations

Engine rpm greater than speed-switch

setting \1

Engine rpm less than speed-switch

setting \1

Factory Pre-set at 23 psi

Non-adjustable \2

2nd Mode Low Engine

Speed Operations

Power on Power off 3 psi below oil

pressure at Idle rpm\3

Table Footnotes: 1. Speed switch operation and adjustment is described in following sections. 2. The 1st mode alarm switch is internal to the gauge and is not adjustable.

It is pre-set to activate when oil pressure falls below 23 psi. 3. The 2nd mode alarm switch should be set at 3 psi below the minimum

idle-speed oil pressure specified on the Base Engine Data Sheet.

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Engine Oil Pressure Gauge Installation


The engine oil pressure gauge must be connected to the engine using #4 USCG type A1 hose or equivalent (Not Supplied). All electrical connections are made through the wiring harness connection.

Install Connecting Hose:

1. Consult the appropriate Engine Installation Diagram for the location and specifications of the oil pressure gauge connection point on the engine. Locate the "ENGINE OIL" connection point (1/4" NPT) on the bottom of the instrument panel.

2. Determine the appropriate length of hose, and route the hose between the connection points.

3. Connect the hose to the engine and the instrument panel using appropriate adapters (Not Supplied).

Marine Gear Oil-Pressure Gauge & Alarm

The marine gear oil pressure gauge indicates marine gear oil pressure and also provides a low oil pressure warning alarm. The operating mode and warning states of the alarm are shown in Table 2.

TABLE 2: Marine Gear Oil Pressure Alarm Modes ALARM MODE

CONDITION MONITORED

ALARM ENABLED

ALARM DISABLED

ALARM SET POINT

Single Mode Alarm

Normal Engine Speed Operations

Engine rpm greater than speed-switch

sett ing \ 1

Engine rpm less than speed-switch

setting \1

See Marine Gear Mfr. Specification

Table Footnote:

^ Speed switch operation and adjustment is described in following sections.

Marine Gear Oil Pressure Gauge Installation


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• The oil pressure pulsation damper supplied with the panel must be installed at the gear oil pressure connection. Failure to install the pulsation damper will result in damage to the gauge.

The marine gear oil pressure gauge must be connected to the engine using #4 USCG type A1 hose or equivalent (Not Supplied). All electrical connections are made through the wiring harness connection.

Install Connecting Hose and Pulsation Damper(s):

1. Consult the gear manufacturer's recommendations for the location and specifications of the gear oil pressure gauge connection point on the gear. Locate the "GEAR OIL" connection point (1/4" NPT) on the bottom of the instrument panel.


3. Install the Pulsation damper in the pressure connection at the marine gear. If additional damper is used, it should be installed between the gauge and the oil pressure line. Use appropriate adapters (Not Supplied) as required.

4. Connect the hose to the engine and the instrument panel. Use appropriate adapters (Not Supplied) as required.

Engine Speed Switch

The Engine Room Panel is equipped with an adjustable Engine Speed Switch located inside the panel box, Figures 9, 10.

FIGURE 9 FIGURE 10

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In operation, the Speed Switch activates or deactivates elements of the engine oil pressure and gear oil pressure alarm systems depending on whether engine speed is above or below the Speed Switch setting. This prevents false alarms from sounding when oil pressures are low due to normal low speed operations. Table 3 provides further description of the alarm modes controlled by the Engine Speed Switch.

TABLE 3: Engine Speed Switch Control Modes

Engine Speed Engine Oil Pressure Alarm Gear Oil Pressure

Alarm Sounds Above the Speed Switch Setting (Typically 1100 rpm)

Sounds if oil pressure falls below the factory preset 23 psi.

Sounds if gear oil pressure falls below the user set pressure.

Below the Speed Switch Setting (Typically 1100 rpm)

Sounds if engine oil pressure falls below the user-set pressure.

Alarm does not operate at engine speeds below the Speed Switch setting.

The speed switch shares the engine speed signal from the tachometer Speed Sensor. The wiring is completed inside the instrument panel box and no installation for the speed switch is required.

Crankcase Pressure Gauge

The gauge indicates engine crankcase pressure (blowby) and provides a high crankcase pressure warning alarm. It should be noted that the gauge is useful for monitoring changes in engine crankcase pressure but provides only a relative measurement. It cannot be correlated with Laboratory/Dynamometer measurements of crankcase pressure, and must not be used as a substitute blowby measurement for the diagnostic procedure specified in the Cummins Troubleshooting & Repair Manual.

The crankcase pressure gauge must be connected to the engine using #4 USCG type A1 hose or equivalent (Not Supplied).

Crankcase Pressure Gage Installation


• The crankcase pressure connection hose must be routed with a continuous upward slope from the engine toward the instrument panel with no dips where oil may collect.

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Install Connecting Hose:

1. Consult the appropriate Engine Installation Diagram for the location and specifications of the crankcase pressure gauge connection point on the engine. Locate the "CRANKCASE" connection point (1/4" NPT) on the bottom of the instrument panel.


3. Connect the hose to the engine and the instrument panel using appropriate adapters (Not Supplied).

Engine Coolant Temperature Gauge & Alarm

The engine coolant temperature gauge indicates coolant temperature and provides a high coolant-temperature alarm. The gauge is mechanical, diaphragm-actuated and is supplied with an attached 7.62 m (25') capillary tube and temperature sensing bulb. The alarm set-point is adjustable at the front of the gauge.

Coolant Temperature Sensor Installation

• The coolant temperature sensor capillary tube must not be sharply kinked or crushed and must not be cut. Any excess length must be smoothly coiled and secured in an area where it will not be damaged.

1. Refer to the appropriate engine installation diagram for location and specifications of the coolant temperature port.

2. Install the temperature sensor bulb using appropriate adapters to position the bulb fully into the coolant passage without contacting other internal surfaces.

3. Route the capillary tube to the instrument panel such that it will not be subjected to physical damage or high temperatures and will not interfere with normal engine room activities.

4. Coil and secure any excess length of capillary tube where it will not be damaged.

Exhaust Temperature Pyrometer

The exhaust temperature pyrometer(s) indicates engine exhaust stack temperature(s). During engine operation the pyrometer(s) should be monitored for significant changes from "normal" exhaust temperatures, but due to wiring harness variations the gauge reading cannot be interpreted as actual exhaust temperature.

Laboratory tests using a 10 ft. long extension wiring harness have shown the pyrometer readings to average 6.4% higher than actual exhaust temperature

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over a range of 850° F (454° C) to 1200° F (649° C). In general, the gauge readings may be 6% to 10% higher than actual temperatures, and the variation may be expected to be greater with longer extension harnesses.

The pyrometer(s) is supplied with appropriate thermocouple(s) which must be installed in the engine exhaust stack. Panels for Vee engines, K38 and K50, are supplied with a dual pyrometer and 2 thermocouples, one for each cylinder bank.

Thermocouple Installation

1. Consult the appropriate Engine Installation Diagram for the proper exhaust temperature thermocouple port location and specifications.

2. Install the thermocouple in the exhaust stack using appropriate adapters (Not Supplied) as required. Use only adapters suitable for use at high temperatures.

3. Discard the thermocouple cable supplied with the pyrometer. Locate the male and female bullet connectors on the marine OEM engine wiring harness and connect them to the thermocouple leads using appropriate adapters as required. Any extension wiring, adapters, connectors or insulating material used must be suitable for high temperature applications.

NOTE: If the Pilot House Panel is NOT being installed proceed to Section: "Engine Room Panel - Calibrations & Adjustments".

CAUTION!

Before Beginning Installation:

1. Disconnect all electrical power to the engine. 2. Make sure the engine cannot be started during

installation.

Pilot House Panel - Functions and Connections

This section describes the functions and connection requirements for the Pilot House Panel gauges. Adjustment and testing of all gauge alarms and other calibrations requiring power-on and/or engine running will be performed after panel installation is complete.

Alarm Annunciator

The alarm annunciator monitors the alarm systems and provides visible and audible fault warnings at the instrument panel station. When a fault is detected a horn sounds at the panel station and individual warning lights on the panel for Engine Oil Pressure, Engine Coolant Level and Temperature, Engine Crankcase Pressure, and Gear Oil Pressure light up to indicate the source of the fault. A

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built-in time delay is provided to allow engine parameters to reach normal levels after start-up without sounding nuisance alarms.

For Engine Oil Pressure the alarm annunciator monitors both alarm modes; 1st mode (low engine speed operation), and 2nd mode (normal engine speed operation). Either fault condition will activate the "Engine Oil Pressure" alarm on the annunciator.

For "Engine Coolant" the alarm annunciator monitors both engine coolant "level" and engine coolant "temperature". A fault condition of either type will activate the "Engine Coolant" annunciator signals.

The annunciator panel is equipped with a "Power On" indicator light and a "Alarm Silence/Test" button. The "alarm silence" function provides a convenient way for the operator to silence the alarm horn after a fault has been indicated. It is still necessary, of course, to determine and correct the cause of the alarm.

The "test" function allows the operator to press the button to verify that all annunciator lights are functional. It is important to note that the "test" function tests ONLY the operation of the annunciator panel lights, and does NOT indicate that the alarm system is functioning properly. Instructions for "Alarm System Tests" are provided in the last section of this bulletin.

The alarm annunciator is fully connected through the extension harness and no further installation is required.

Tachometer

The Pilot House Panel is supplied with a digital tachometer driven by engine speed signals relayed from the Engine Room Panel tachometer. Panels for QSK engines may be equipped with an optional analog tachometer in place of the digital model. This tachometer is identical to that in the Engine Room Panel. Either tachometer must be calibrated following instructions provided in the following sections. All electrical and data connections are made through the Pilot House Extension Harness.

Engine Coolant Temperature Gauge

The Pilot House Panel coolant temperature gauge is an electrical gauge which operates independently of the mechanical gauge used in the Engine Room Panel. This gauge uses a separate electrical temperature sensor which must be installed in the engine and connected to the marine OEM Engine Harness. Subsequent electrical connections to the Pilot House Panel are made through the Remote Panel Extension Harness, and no further installation is required.

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Coolant Temperature Sensor Installation

1. Consult the appropriate Engine Installation Diagram for location and specifications of the proper coolant temperature port, and install the temperature sensor using appropriate adapters as required.

2. Connect the electrical leads from the Marine OEM Engine Wiring Harness to the terminals on the sensor.

Engine Coolant Level Gauge & Alarm

The Engine Coolant Level Gauge, Figure 11, contains an internal float that monitors engine coolant level in the expansion tank. In the event of low coolant level the gauge sounds an alarm on the Pilot House Panel annunciator.

Coolant Level Gauge Installation

The engine coolant level gauge must be installed on or near the coolant expansion tank. Where possible the gauge should be mounted on the side of the cooling system expansion tank. Some Cummins supplied expansion tanks have provisions for mounting the coolant level gauge on the side of the tank (refer to the Engine Installation Diagram). Where these are available they should be used. If the expansion tank being used does not provide attachment points and/or connection ports these must be customer supplied.

If mounting on the expansion tank is not possible, the gauge may be mounted on a nearby bulkhead or on appropriate, brackets (Not Supplied) attached to the engine. The gauge must be mounted as close to the expansion tank as possible.

Electrical connections to the panel are made through the connector on Marine OEM Engine Harness.

1. Locate and orient the gauge such that the gauge "LOW" mark is even with the Low Coolant Level condition in the tank, and the gauge is as level (horizontal) as possible under normal vessel operating conditions.

FIGURE 11

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2. Mount the gauge using the mounting tabs provided on the gauge. (Mounting tab holes are 7 mm (9/32 in.) diameter on 114 mm (4 1/2 in.) centers.)

3. Use suitable coolant hose and adapters (Not Supplied) as required to connect the gauge coolant connection to a connection port on or near the bottom of the expansion tank. The coolant connection at the tank must be located to be below the coolant level in the tank at all times.

4. Use suitable coolant hose and adapters (Not Supplied) as required to connect the gauge vent to a user supplied connection on or near the tog of the expansion tank. The vent connection at the tank must be located to be above the coolant level in the tank at all times.

5. Connect the three-pin connector provided in the Marine OEM Engine Harness to the gauge electrical connector.

Restore Power to Electrical Systems

1. Verify that all mechanical and electrical connections have been properly made and are secure.

2. Verify that all harness connections are made and secure.

3. Set the LOCAL/REMOTE switch on the Engine Room Panel and the keyswitch on the Pilot House Panel to OFF.

4. Restore electrical power to engine systems.

5. Switch the local / remote switch on the Engine Room Panel to "LOCAL". This should cause the "SYSTEM POWER" and "WARNING" lights to light up.

Engine Room Panel - Calibrations & Adjustments

Some calibrations and alarm set-point adjustments require system power on (See preceding section "Restore Power to Electrical Systems".) and/or engine running at operating temperature. These procedures are best performed at sea trial when the engine and vessel are fully operational.

Engine Oil Pressure Alarm Adjustment

1. Determine the minimum idle-speed oil-pressure from the appropriate General Engine Data Sheet.

2. Adjust the alarm contact setting at the front of the gauge using a 1/16" alien wrench to move the alarm contact switch.

• The indicator needle will move with the contact switch as the adjustment screw is turned.

• The gauge is properly set when the indicator needle is at 3 psi below the specified minimum idle-speed oil pressure.

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Gear ON Pressure Alarm Adjustment

1. Determine the minimum marine gear oil-pressure from the gear manufacturer's specifications.

2. Adjust the alarm setting at the front of the gauge using a 1/16" alien wrench to move the alarm contact switch.

• The indicator needle will move with the contact switch as the adjustment is screw is turned.

• The gauge is properly set when the indicator needle is at the specified minimum oil pressure.

Crankcase Pressure Gauge Alarm Adjustment

Proper adjustment of the crankcase pressure alarm requires data from sea trials and cannot be performed prior to these tests.

1. The crankcase pressure alarm can be properly set only during/after sea trials. Prior to sea trials the alarm should be adjusted well above the anticipated crankcase pressure level to avoid nuisance alarms while other adjustments and procedures are being performed.

2. During sea trials observe the indicated crankcase pressure while operating at full throttle (maximum load).

3. Adjust the alarm contact setting at the front of the gauge using a 1/16" Allen wrench. The recommended setting is 8 inches H2O above the highest

pressure observed during full throttle, maximum load, operation.

Engine Coolant Temperature Gauge Alarm Adjustment

1. Determine the recommended maximum engine coolant temperature setting from the appropriate General Engine Data Sheet.

2. Use a 1 /16" Allen wrench at the front of the gauge to adjust the alarm contact switch to the desired temperature.

Engine Speed Sensor Voltage Check

• Customer add-on devices using the Engine Speed Sensor signal must not significantly degrade signal voltage. Signal voltage at both tachometers (engine room and pilot house) and the speed switch must be greater than 6.0 volts, peak-to-peak, measured at the tachometer and speed switch terminals with all add-on devices operating and engine speed at low-idle.

The following procedure is required only if customer supplied add-on devices are connected to the engine Speed Sensor signal.

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The voltage check is required to assure sufficient signal voltage for tachometers and the speed switch. It is important to note that "signal" voltage is separate from the 12 or 24 volt, DC "system" voltage. Signal voltage is an alternating current voltage generated by the Speed Sensor. It must be measured as an AC voltage.

1. Start the engine and allow it to warm up to normal operating temperature.

2. With the engine running at low-idle speed, measure peak-to-peak signal voltage at: a) Engine Room Panel tachometer, b) Engine Room Panel speed switch, and c) Pilot House Panel tachometer.

3. Speed Sensor signal voltage at all points must be greater than 6.0 volts peak-to-peak with the engine running at low-idle.

If the signal voltage is too low with the add-on device attached it will be necessary to install an additional engine Speed Sensor (Not Supplied) to drive the add-on device.

Tachometer Calibration

Tachometer calibration is a two-step procedure requiring a "Coarse Adjustment" and a "Fine Adjustment". The tachometer calibration controls are reached by opening the front cover of the instrument panel. Figure 12 shows the back of the tachometer indicating the calibration adjustment controls.

FIGURE 12

Coarse Adjustment:

1. Set up a calibrated hand-held tachometer similar to Cummins P/N 3377462 to monitor the engine's true RPM. On electronic control engines you may use INSITE in place of the hand-held tachometer.

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2. Using Table 4, below, and SAE flywheel size, determine the number of teeth on the engine flywheel. (If the number of teeth on the flywheel cannot be determined use the "Alternate Coarse Adjustment" instructions given below.)

3. With the engine OFF, use a small, flat blade screw-driver to set the calibration "coarse adjustment switch" to the correct switch position shown in Table 4.

4. Proceed to the "fine adjustment" procedure.

Alternate Coarse Adjustment:

If the number of flywheel ring-gear teeth cannot be determined use the following procedure. 1. Start the engine and allow it to warm up to operating temperature.

2. Using the hand held tachometer increase engine speed to normal, rated RPM.

3. With the engine running at rated speed, use a small, flat blade screw-driver to set the calibration "coarse adjustment switch" to the position that gives the tachometer reading closest to true RPM (as indicated on the hand-held tachometer).

4. Proceed to the "fine adjustment" procedure.

TABLE 4: Tachometer Coarse Adjustment Data

FLYWHEEL SIZE NUMBER OF RING-

GEAR TEETH COARSE

ADJUSTMENT SWITCH POSITION

SAE No. 1 Flywheel 118 teeth 3 SAE No. 0 Flywheel 142 teeth 4

SAE No. 00 Flywheel 168 teeth 5

Fine Adjustment:

The "fine adjustment" calibration is accomplished by adjusting the trimpot located behind the "fine adjustment" access hole on the rear of the case. Figure 12 above.

1. Start the engine and allow it to warm up to normal operating temperature.

2. Carefully punch through the paper label on the back of the tachometer to expose the adjustment access hole and insert a 5/64 in. (2 mm) hex-end Allen wrench into the fine adjustment trimpot.

3. Use the hand-held tachometer (or INSITE) to set the engine RPM at rated speed.

4. With the engine running at rated RPM slowly rotate the trimpot clockwise or counterclockwise, as necessary, to bring the instrument panel tachometer RPM reading to match that of the hand-held tachometer.

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5. When the instrument panel tachometer and the hand-held tachometer read the same the calibration is complete.

Engine Speed Switch Adjustment

The Engine Room Tachometer must be properly calibrated before attempting to adjust the Engine Speed Switch setting.

The Speed Switch setting must be adjusted to the desired engine speed. Typically, a setting of 1100 rpm provides good protection with minimal nuisance alarms. Figure 10 above shows adjustment controls and indicators on the speed switch.

1. Start the engine and confirm that the speed switch "PICKUP" light is on. This indicates the switch is receiving a signal. If this light is not on, troubleshoot the engine Speed Sensor / tachometer system to determine why there is no signal.

2. Using a small, flat-blade screwdriver turn the "SPEED ADJ." potentiometer screw clockwise 20 complete turns to clear any previous settings. The potentiometer does not have "stops" at the extreme settings. You must count the turns.

3. Using the instrument panel tachometer (previously calibrated) set the engine speed to 1100 rpm.

4. With the engine running at 1100 RPM, turn the "SPEED ADJ." potentiometer screw counter-clockwise until the "ENERGIZE" light turns on. Adjust the potentiometer slightly back and forth as required to reach the exact point where the light just comes on.

Pilot House Panel - Calibrations & Adjustments

Pilot House Panel gauges are electrically driven. The engine oil pressure and gear oil pressure gauges are driven by transducers in the Engine Room Panel, and the engine coolant temperature gauge is driven by the previously installed temperature transducer. All connections are made through the Pilot House Panel Extension Harness, and all alarm functions are driven from the Engine Room Panel gauges. In the Pilot House Panel only the tachometer requires adjustment or calibration.

The Pilot House Panel tachometer may be either a digital or analog model (optional on QSK engine applications only). The analog model is identical to the analog tachometer used in the Engine Room Panel and is calibrated using the same procedure. The calibration procedure for the digital tachometer are given below.

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Analog Tachometer Caiibration (Optional for QSK engines only)

Calibration procedure for this tachometer is the same as for the Engine Room Panel Tachometer. Refer to previous procedures for Engine Room Panel Tachometer Calibration.

Digital Tachometer Calibration

CAUTION: To reduce the chance of accidental contact with live electrical terminals while calibrating the digital tachometer set the Remote/Off/Local toggle switch on the Engine Room Panel to the "OFF" position.

The digital Pilot House Panel tachometer is calibrated using three, 10-position rotary switches located under the rubber cover on the back of the tachometer, Figure 13.

1. From the back of the Pilot House Panel locate the calibration switches.

2. Determine the Flywheel SAE size or number of ring-gear teeth and using Table 5, below, to establish the correct setting for each of the three switches. The three switches (Left, Center and Right) must be "set" to indicate the number of teeth on the flywheel ring-gear as shown in the table.

3. Calibration is accomplished by turning the center indicator of each switch with a small screw driver until the indicator arrow (small white dot) is adjacent to the desired number.

FIGURE 13

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TABLE 5. Digital Tachometer Adjustment Data

FLYWHEEL SIZE NUMBER OF RING-GEAR

TEETH

LEFT SWITCH

100's

CENTER SWITCH

10's

RIGHT SWITCH

1*s SAE No. 1 Flywheel

118 teeth "1" "1" "8"

SAE No. 0 Flywheel

142 teeth "1" "4" "2"

SAE No. 00 Flywheel

168 teeth "1" "6" "8"

Alarm System Tests • The panel alarm system must be fully adjusted and tested before or

during sea-trials.

The panel alarm system must be fully tested before and during sea trials. The tests are conducted by individually "misadjusting" the alarm set-points to simulate an alarm condition and observing the alarm annunciator response. Unless otherwise noted the test settings are made at the Engine Room Panel using a 1/16 inch Allen wrench at the adjustment point on the face of the gauge.

Since the alarm adjustments are located on the Engine Room Panel and the annunciator is on the Pilot House Panel it will be necessary to have a person stationed at each position with communications between them during the testing.

The following instructions assume that the previous procedures for initial gauge alarms settings have been completed. Successful completion of the following tests will assure proper operation of the alarm systems.

Alarm Annunciator Lights

1. With system power on, engine not running; set the LOCAL/REMOTE switch in REMOTE position.

2. Press the "test" button on the Pilot House Panel. All alarm annunciator lights should come on and remain on while the button is held down, and the warning horn should sound.

3. Switch the LOCAL/REMOTE switch to the LOCAL position.

4. Press the "test" button on the Pilot House Panel. All alarm annunciator lights should come on and remain on while the button is held down, and the warning horn should sound.

Engine Coolant Alarm (Coolant Level Low)

1. With system power on, engine not running, turn the Alarm Test Knob, located at the right side of the indicator glass, counter-clockwise until the indicator contacts and trips the low-level indicator switch.

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2. The "WARNING" lamp on the Engine Room Panel should light, and the "ENGINE COOLANT" lamp on the Pilot House Panel annunciator should light. The warning horn should sound.

3. Release the knob; the indicator should return to the previous level and the alarms extinguish.

Engine Coolant Alarm (Coolant Temperature High)

1. With system power on, engine not running, note the initial setting of the alarm contact in the Engine Room Panel gauge; then move the alarm contact until it just touches the indicator needle.

2. The "WARNING" lamp on the Engine Room Panel should light, and the "ENGINE COOLANT" lamp on the Pilot House Panel annunciator should light.

3. After verifying alarm operation, move the contact back to the original position. The "WARNING" lamp and the "ENGINE COOLANT" lamp should extinguish.

Crankcase Pressure Alarm

1. With system power on, engine not running, note the original setting of the alarm contact in the Engine Room Panel gauge then move the alarm contact until it just touches the indicator needle.

2. The "WARNING" lamp on the Engine Room Panel should light, and the "ENGINE CRANKCASE PRESSURE" lamp on the Pilot House Panel annunciator should light.

3. After verifying alarm operation, move the alarm contact back to the original position. The "WARNING" lamp and the "ENGINE CRANKCASE PRESSURE" lamp should extinguish.

Engine Oil Pressure Alarm - Low Engine Speed Operation

1. Start the engine, and run at idle speed. Allow the engine to come up to full operating temperature.

2. With the engine running at idle speed, note the original setting of the alarm contact in the Engine Room Panel gauge then move the alarm contact until it just touches the indicator needle.

3. The "WARNING" lamp on the Engine Room Panel should light, and the "ENGINE OIL PRESSURE" lamp should be lit on the pilothouse annunciator.

4. After verifying engine oil pressure alarm operation, move the alarm contact back to the original position. The "WARNING" lamp and the "ENGINE OIL PRESSURE" lamp should go out.

Engine Oil Pressure Alarm - Normal Engine Speed Operation

1. Start the engine, and run at idle speed. Allow the engine to come up to full operating temperature.

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2. To temporarily deactivate the Marine Gear pressure alarm, note the original setting of the Marine Gear gauge contact, then use a 1/16" Allen wrench to move the contact well away from (below) the indicator needle.

3. Open the panel to access the speed switch, and turn the speed switch potentiometer clockwise until the "SPEED ADJ." LED indicator turns on. (See previous Speed Switch adjustment instructions for speed switch location and control identification.)

4. At this point, if the engine oil pressure is below 159 kPa (23 psi), the "WARNING" lamp on the Engine Room Panel should light, and the "ENGINE OIL PRESSURE" lamp should light on the pilothouse annunciator.

5. Do NOT readjust the speed switch at this time.

Marine Gear Oil Pressure Alarm

1. Move the contact in the marine gear oil pressure gauge back to the original gauge contact setting. This adjustment will make contact with the alarm switch and activate the alarm.

2. The "WARNING" lamp on the Engine Room Panel should light, and the "GEAR OIL PRESSURE" lamp should be lit on the pilothouse annunciator.

Engine Speed Switch - Reset

Increase the engine speed to the previously determined switch point speed (1100 RPM is recommended, see previous instructions for adjusting the speed switch).

With the engine running at the set-point speed, turn the Speed Switch, SPEED ADJ. potentiometer screw counterclockwise until the PICKUP LED light comes on. Refer to the previous Speed Switch adjustment procedure.

When the speed switch is reset to the previous switch point speed the "ENGINE OIL PRESSURE" and "GEAR OIL PRESSURE" alarm indicators should be extinguished.

Change Log

Date Change Page Revising Author's

Name 11/09/2005 No content change/Uploaded to web site DDC

Distribution of this document is intended for Cummins personnel and distributors. The information contained in this document is only considered valid while published on the Marine Website. Copies and archived documents are not considered current

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