inst for prem instru panels

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Cummins Confidential

Subject:

Instructions for PremiumInstrument Panels

This AEB is for the following applications:

Automotive

Industrial

G-Drive

Marine

Date Created: 05/03/2003

Revision Date: 07/15/2008

Expire Date: 07/13/2011

File Name : 0.15.00

Controls, Gauges &

Alarms

MAB No.

0.15.00-05/03/2003

Engine Family : All

Engine Model : All

Document Owner : J ohn Yancone of 30

Purpose

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

Introduction

The Premium Panel Series is a family of instrument panel and wiring harnessoptions available for Cummins Marine Heavy Duty and High Horsepowerengines. The option series includes many common components with minordesign differences between panel sets for mechanically controlled andelectronically controlled (CENTRY or Quantum) engines.



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

Engine Room Harnesses 6Pilot House Extension Harness 7

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

Pilot House Panel - Functions and Connections 14

Alarm Annunciator 14 Tachometer 15Engine Coolant Temperature Gauge 15Engine Coolant Level Gauge & Alarm 15

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

Summary of Installation Requirements

• Use of the Engine Room Panel without

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

the Pilot House Panel requiresinstallation of a remote start/stop switch, a low oil pressure alarm, and ahigh coolant temperature alarm.

• The Engine Room Panel must be located near the engine within the 25ft. 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 theEngine Room Panel. It is driven by electrical senders inc luded in theEngine Room Panel and will not operate properly wi thout the EngineRoom Panel.



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• Wiring harnesses must be located where the harness wil l not besubjected to physical damage or high temperatures and will notinterfere with normal engine room or pilot house activities. Harnessesmust be supported in a cable race or by a continuous series of cableclips 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 ft., voltage at the Pilot House Panel must be measured toassure a minimum of 10.0 Volts (20.0 Volts for 24 volt systems) toassure 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 serviceinstruments.

• 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 signalmust not degrade signal voltage. Signal vol tage 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 operatingand engine speed at low-idle

• Hoses must be routed where they will not be subjected to physicaldamage or high temperatures and will not interfere with normal engineroom activities.

.

• The oil pressure pulsation damper supplied with the panel must be

installed at the marine gear oil pressure connection. Failure to installthe pulsation damper will resul t in damage to the pressure sender.

• The crankcase pressure connection hose must be routed with acontinuous upward slope from the engine toward the instrument panelwith no dips

• The coolant temperature sensor capil lary tube must not be sharplykinked or crushed and must not be cut. Any excess length must besmoothly coi led and secured in an area where it wil l not be damaged.

where oil may collect.

• The panel alarm system must be ful ly 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 forpanels and wiring harnesses and calibration and adjustment proceduresinstruments 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, LowEngine Coolant Level, High Engine Coolant Temperature, HighCrankcase-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.

Before Beginning Installation:

CAUTION!

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

Panel Mounting Instruct ions

• Use of the Engine Room Panel

Engine Room Panel

without

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

the Pilot House Panel requiresinstallation of a remote start/stop switch, a low oil pressure alarm, and a

high coolant temperature alarm.

• The Engine Room Panel must be located near the engine within the 25ft. 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 allalarms and gauges. Installations using only the engine room panel must includethe following (not supplied):

1. A start/stop switch must be installed in the main pilot house to allowthe operator to remotely shut off the engine. For all engines exceptQSK19-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 theremote extension harness). QSK19-M engines require the switchinstallation across the battery power and key switch circuits (pins Band D at the connector for the remote extension harness). Refer to theappropriate 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 bedriven either by the switch gauges (which can output a maximum of two amps at rated voltage). in the engine room panel or by externalalarm switches.

The engine room panel should be mounted so that is easily accessible by anoperator and such that the engine can be observed during start-up and shut-down. Typical panel mounting locations include attachment to overheadstructure, bulkheads, or foundation posts. Panels may be surface mounted from

the sides, or mounted with a fabricated angle bracket (not supplied). Fourmounting holes are located on the sides of the panel box.

Pilot House Panel

• The Pilot House Panel must be installed only in combination with theEngine Room Panel. It is driven by electrical senders inc luded in theEngine Room Panel and will not operate properly wi thout the EngineRoom Panel.

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

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



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Figure 1: Dimensions for the bezel

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

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

Wiring Harness Installation

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



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

FIGURE 2: Harness Connections

MARINE OEM

ENGINE HARNESS

ENGINE ROOM

EXTENSION HARNESS

ENGINE ROOM

PANEL

ENGINE

HARNESS

FIGURE 3: Harness Connections

ENG.ROOM

EXTENSION

HARNESS ENGINE ROOM

PANEL

PILOT HOUSE

PANEL

PILOT HOUSE

EXTENSION HARNESS

Engine Harness

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

Figure 4: Connectors on the engine

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

Marine OEM Engine Harness



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

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

3. Secure the Marine OEM Engine Harness in place on the engine usingbrackets, clips and wire-ties provided. For K19 and K-Vee applicationsconnector brackets are not provided

with the harness and must be fabricated. The brackets should be attached to the engine and must support theconnectors to prevent chafing and vibration damage.

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

Engine Room Extension Harness

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 placeusing appropriate supports (Not Supplied).

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

Figure 5: Engine room panel connectors



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Pilot House Extension Harness

• If the total length of the extension harness to the Pilot House Panelexceeds 150 ft., voltage at the Pilot House Panel must be measured toassure 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 serviceinstruments.

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

The Pilot House Extension Harness provides all connections for gauges andcontrols on the Pilot House Panel and includes the Data Link Connector (for

CENTRY Engine applications). The harness provides Deutsch connector(s) tothe Engine Room Panel and flying leads for connection to the terminal strip at theback of the Pilot House Panel, Figure 6. In general, it will be necessary to cutthe Pilot House Extension Harness to length and prepare the leads forconnection to the terminal strip as described below.

Figure 6: Pilot house panel terminal strip Figure

1. Pilot-house panel extension harnesses are available in 50, 100, and 150 footlengths. 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 insulationand tin (solder) the wire ends for attachment to the panel terminal strip inselecting the length of the harness.

4. At the Pilot House Panel end, trim the harness to the desired length. Be sureto allow sufficient length to strip insulation, tin (solder) the leads and connect



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to the panel terminal strip. Do not cut the harness at the Deutsch connectorend

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

.

•

For ease of installation the terminal strip may be temporarily loosenedfrom the panel as shown in Figure 7 above. To loosen the terminalstrip, remove the hex nuts at either end of the strip.

• Some wire-ties may need to be cut to free up the terminal strip. Besure to retie these when the terminal strip is replaced. If panel wiresare disconnected for easier access be sure to note their positions forcorrect reconnection.

• For ease of identification it is recommended that each wire be labeledwith the corresponding wire number as given in the appropriate WiringDiagram. Figure 8 shows the terminal strip with labeled wiresattached.

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

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

• After all wires are securely attached to the terminal strip re-attach thestrip 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: Terminal strip with leads attached



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Engine Room Panel - Functions; Connections:

This section describes the functions and connection requirements for each of theEngine Room Panel gauges. Adjustment and testing of all gauge alarms andother calibrations requiring power-on and/or engine running will be performed

after panel installation is complete.

Tachometer / Hour-meter

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

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 pickupgenerate an alternating-current electrical signal. Peak to peak voltage of thesignal may vary from 6.0 volts to 85.0 volts depending on gear toothconfiguration, relative surface speed of the gear teeth (engine speed) and gapclearance to the Speed Sensor.

Speed Sensor Signal

• 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.

Speed Sensor Installation

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

2. Remove the plug from the flywheel housing port (if required) and bar theengine 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 thesensor just touches the top of the ring-gear tooth. Then, turn the sensor out(counter-clockwise) ½ 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).

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

Do not allow the sensor to turn while tightening the lock nut.

Customer Add-On Devices Requiring Speed Sensor Signal



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• Customer add-on devices using the Engine Speed Sensor signal mustnot degrade signal voltage. Signal voltage at both tachometers (engineroom and pilot house) and the speed switch must be greater than 6.0volts , peak-to-peak, measured with all add-on devices operating andengine running at low-idle

.

The Speed Sensor is designed to provide the speed signal to the instrumentpanel tachometers and speed switch.Other devices requiring an engine speed signal may be connected to the sensoroutput, but caution must be exercised to assure that the additional electrical loaddoes not degrade the signal. A degraded or altered signal may causeunacceptable performance of the tachometers or speed switch.

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

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

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 tothe terminals. Be sure all leads are securely reattached. Note: The steelframe of the panel is electrically isolated from all circuitry. It is not connectedto 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 providestwo 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 ModeNormal

Engine Speed

Operations

Engine rpmgreater than

speed-switchsetting\1

Engine rpm lessthan speed-switch

setting\1

Factory Pre-set at23 psi

Non-adjustable\2

2nd ModeLow Engine

SpeedOperations

Power on Power off

3 psi below oilpressure at Idle

rpm\3



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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.

Engine Oil Pressure Gauge Installation


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

Install Connecting Hose:

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

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

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

Marine Gear Oil-Pressure Gauge & Alarm

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

TABLE 2: Marine Gear Oil Pressure Alarm Modes

ALARMMODE CONDITIONMONITORED ALARMENABLED ALARMDISABLED ALARMSET POINTSingleModeAlarm

Normal EngineSpeedOperations

Engine rpmgreater thanspeed-switch

setting\1

Engine rpmless thanspeed-switch

setting\1

See MarineGear Mfr.Specification

Table Footnote: 1 Speed switch operation and adjustment is described in following sections



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Marine Gear Oil Pressure Gauge Installation


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

The marine gear oil pressure gauge must be connected to the engine using #4USCG type A1 hose or equivalent (Not Supplied). All electrical connections aremade 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 theinstrument 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 andthe oil pressure line. Use appropriate adapters (Not Supplied) as required.

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

Engine Speed Switch

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



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Figure 9: Speed Switch Location Figure 10: Speed Switch

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

TABLE 3: Engine Speed Switch Control Modes

Engine Speed Engine Oil Pressure AlarmGear Oil Pressure

Alarm Sounds

Above the Speed

Switch Setting

(Typically 1100 rpm)

Sounds if oil pressure falls below

the factory p reset 23 psi.

Sounds if gear oilpressure falls below

the user setpressure.

Below the SpeedSwitch Setting(Typically 1100 rpm)

Sounds if engine oil pressure fallsbelow the user-set pressure.

Alarm does not

operate at enginespeeds below theSpeed Switch setting.

The speed switch shares the engine speed signal from the tachometer SpeedSensor. The wiring is completed inside the instrument panel box and noinstallation for the speed switch is required.

Crankcase Pressure Gauge

The gauge indicates engine crankcase pressure (blowby) and provides a highcrankcase pressure warning alarm. It should be noted that the gauge is usefulfor monitoring changes in engine crankcase pressure but provides only a relativemeasurement.



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It cannot be correlated with Laboratory/Dynamometer measurements of crankcase pressure, and must not be used as a substitute blowby measurementfor the diagnostic procedure specified in the Cummins Troubleshooting & RepairManual.

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

Crankcase Pressure Gage Installation


• The crankcase pressure connection hose must be routed with acontinuous upward slope from the engine toward the instrument panelwith no dips

where oil may collect.

Install Connecting Hose

1. Consult the appropriate Engine Installation Diagram for the location andspecifications of the crankcase pressure gauge connection point on theengine. Locate the "CRANKCASE" connection point (1/4" NPT) on thebottom of the instrument panel.


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

Engine Coolant Temperature Gauge & Alarm

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

• The coolant temperature sensor capil lary tube must not be sharplykinked or crushed and must not be cut. Any excess length must besmoothly coi led and secured in an area where it wil l not be damaged.

Coolant Temperature Sensor Installation

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



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2. Install the temperature sensor bulb using appropriate adapters toposition the bulb fully into the coolant passage without contacting otherinternal surfaces.

3. Route the capillary tube to the instrument panel such that it will not besubjected 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 bedamaged.

Exhaust Temperature Pyrometer

The exhaust temperature pyrometer(s) indicates engine exhaust stacktemperature(s). During engine operation the pyrometer(s) should be monitoredfor significant changes from "normal" exhaust temperatures, but due to wiringharness variations the gauge reading cannot be interpreted as actual exhausttemperature.

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

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

The pyrometer(s) is supplied with appropriate thermocouple(s) which must beinstalled in the engine exhaust stack. Panels for Vee engines, K38 and K50, aresupplied 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 (NotSupplied) as required. Use only adapters suitable for use at hightemperatures.

3. Discard the thermocouple cable supplied with the pyrometer.

Locate themale and female bullet connectors on the marine OEM engine wiring harnessand connect them to the thermocouple leads using appropriate adapters as

required. Any extension wiring, adapters, connectors or insulating materialused 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" .



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CAUTION!

1. Disconnect all electrical power to the engine.

Before Beginning Installation:

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 PilotHouse Panel gauges. Adjustment and testing of all gauge alarms and othercalibrations requiring power-on and/or engine running will be performed afterpanel installation is complete.

Alarm Annunciator

The alarm annunciator monitors the alarm systems and provides visible andaudible fault warnings at the instrument panel station.When a fault is detected a horn sounds at the panel station and individualwarning lights on the panel for Engine Oil Pressure, Engine Coolant Level and Temperature, Engine Crankcase Pressure, and Gear Oil Pressure light up toindicate the source of the fault. A built-in time delay is provided to allow engineparameters to reach normal levels after start-up without sounding nuisancealarms.

For Engine Oil Pressure the alarm annunciator monitors both alarm modes; 1stmode (low engine speed operation), and 2nd mode (normal engine speed

operation). Either fault condition will activate the "Engine Oil Pressure" alarm onthe 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 "AlarmSilence/Test" button. The "alarm silence" function provides a convenient way forthe operator to silence the alarm horn after a fault has been indicated. It is stillnecessary, of course, to determine and correct the cause of the alarm.

The "test" function allows the operator to press the button to verify that allannunciator lights are functional. It is important to note that the "test" functiontests ONLY the operation of the annunciator panel lights

, and does NOT indicatethat the alarm system is functioning properly. Instructions for "Alarm System Tests" are provided in the last section of this bulletin.



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The alarm annunciator is fully connected through the extension harness and nofurther 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 thedigital model. This tachometer is identical to that in the Engine Room Panel.Either tachometer must be calibrated following instructions provided in thefollowing sections. All electrical and data connections are made through the PilotHouse Extension Harness.

Engine Coolant Temperature Gauge

The Pilot House Panel coolant temperature gauge is an electrical gauge whichoperates independently of the mechanical gauge used in the Engine Room

Panel. This gauge uses a separate electrical temperature sensor which must beinstalled in the engine and connected to the marine OEM Engine Harness.Subsequent electrical connections to the Pilot House Panel are made throughthe Remote Panel Extension Harness, and no further installation is required.

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

Coolant Temperature Sensor Installation

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

Engine Coolant Level Gauge & Alarm

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

Figure 11: Coolant level gauge



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The engine coolant level gauge must be installed

Coolant Level Gauge Installation

on or near

the coolantexpansion tank. Where possible the gauge should be mounted on the side of thecooling system expansion tank. Some Cummins supplied expansion tanks haveprovisions for mounting the coolant level gauge on the side of the tank (refer to

the Engine Installation Diagram). Where these are available they should beused. If the expansion tank being used does not provide attachment pointsand/or connection ports these must be customer supplied.

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

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

1. Locate and orient the gauge such that the gauge "LOW" mark is even with theLow Coolant Level

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

condition in the tank, and the gauge is as level (horizontal)as possible under normal vessel operating conditions.

3. Use suitable coolant hose and adapters (Not Supplied) as required toconnect the gauge coolant connection to a connection port on or near thebottom of the expansion tank. The coolant connection at the tank must belocated to be below the coolant level

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

in the tank at all times.

top of the expansion tank. The vent connection at the tank must be located to beabove the coolant level

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

in the tank at all times.

Restore Power to Electr ical Systems

1. Verify that all mechanical and electrical connections have been properlymade 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 thekeyswitch 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". Thisshould cause the "SYSTEM POWER" and "WARNING" lights to light up.

Engine Room Panel - Calibrations & Adjustments



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

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

Engine Oil Pressure Alarm Adjustment

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

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

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

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

Gear Oil Pressure Alarm Adjustment

2. Adjust the alarm setting at the front of the gauge using a 1/16" allen wrench tomove 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.

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

Crankcase Pressure Gauge Alarm Adjustment

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 anticipatedcrankcase pressure level to avoid nuisance alarms while other adjustmentsand procedures are being performed.

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

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

pressure observed during full throttle, maximum load, operation.



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Engine Coolant Temperature Gauge Alarm Adjustment

1. Determine the recommended maximum engine coolant temperaturesetting 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.

• Customer add-on devices using the Engine Speed Sensor signal mustnot signi ficantly degrade signal voltage. Signal voltage at bothtachometers (engine room and pilot house) and the speed switch mustbe greater than 6.0 volts, peak-to-peak, measured at the tachometer andspeed switch terminals with all add-on devices operating and enginespeed at

Engine Speed Sensor Voltage Check

low-idle

.

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

The voltage check is required to assure sufficient signal voltage for tachometersand the speed switch. It is important to note that "signal" voltage is separatefrom the 12 or 24 volt, DC "system" voltage. Signal voltage is an alternatingcurrent voltage generated by the Speed Sensor. It must be measured as an ACvoltage

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

.

2. With the engine running at low-idle

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

speed, measure peak-to-peak signal

voltage at: a) Engine Room Panel tachometer, b) Engine Room Panel speedswitch, and c) Pilot House Panel tachometer.

low-idle

.

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

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

Tachometer Calibration



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Figure 12: Back of the tachometer

Coarse Adjustment:

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

2. Using Table 4, below, and SAE flywheel size, determine the number of teethon the engine flywheel. (If the number of teeth on the flywheel cannot bedetermined

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.

use the "Alternate Coarse Adjustment" instructions given below.)

4. Proceed to the "fine adjustment" procedure.

Alternate Coarse Adjustment :

If the number of flywheel ring-gear teeth cannot be determined

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

use the followingprocedure.

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

3. With the engine running at rated speed, use a small, flat blade screw-driver toset the calibration "coarse adjustment switch" to the position that gives thetachometer reading closest

4. Proceed to the "fine adjustment" procedure.

to true RPM (as indicated on the hand-heldtachometer).



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TABLE 4: Tachometer Coarse Adjustment Data

FLYWHEEL SIZENUMBER OF RING-

GEAR TEETHCOARSE

ADJUSTMENTSWITCH POSITION

SAE No. 1 Flywheel 118 teeth 3SAE No. 0 Flywheel 142 teeth 4SAE No. 00 Flywheel 168 teeth 5

Fine Adjustment:

The “fine adjustment” calibration is accomplished by adjusting the trimpot locatedbehind the “fine adjustment” access hole on the rear of the case, Figure 12above.

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 toexpose the adjustment access hole and insert a 5/64 in. (2 mm) hex-end

Al len wrench into the fine adjustment trimpot.

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

4. With the engine running at rated RPM

5. When the instrument panel tachometer and the hand-held tachometer read

the same the calibration is complete.

slowly rotate the trimpot clockwise orcounterclockwise, as necessary, to bring the instrument panel tachometerRPM reading to match that of the hand-held tachometer.

The Engine Room Tachometer must be properly calibrated

Engine Speed Switch Adjustment

before

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

attempting toadjust the Engine Speed Switch setting.

1. Start the engine and confirm that the speed switch “PICKUP” light is on

2. Using a

. Thisindicates the switch is receiving a signal. If this light is not on, troubleshootthe engine Speed Sensor / tachometer system to determine why there is nosignal.

small, flat-blade screwdriver turn the "SPEED ADJ ." potentiometerscrew clockwise 20 complete turns to clear any previous settings. The



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potentiometer does not

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

have "stops" at the extreme settings. You must countthe turns.

4. With the engine running at 1100 RPM, turn the "SPEED ADJ ." potentiometerscrew counter-clockwise

until the "ENERGIZE” light turns on. Adjust thepotentiometer slightly back and forth as required to reach the exact pointwhere the light just comes on.

Pilot House Panel - Calibrations & Adjustments

Pilot House Panel gauges are electrically driven. The engine oil pressure andgear oil pressure gauges are driven by transducers in the Engine Room Panel,and the engine coolant temperature gauge is driven by the previously installedtemperature transducer. All connections are made through the Pilot HousePanel Extension Harness, and all alarm functions are driven from the EngineRoom Panel gauges. In the Pilot House Panel only the tachometer requiresadjustment 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 theanalog tachometer used in the Engine Room Panel and is calibrated using thesame procedure. The calibration procedure for the digital tachometer are givenbelow.

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

Analog Tachometer Calibration (Optional for QSK engines only)

Digital Tachometer Calibration

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

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



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FIGURE 13: Tachometer adjustment switches

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 usingTable 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 thenumber of teeth on the flywheel ring-gear as shown in the table.

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

TABLE 5. Digital Tachometer Adjustment Data

FLYWHEEL SIZE

NUMBER OF

RING-GEARTEETH

LEFT

SWITCH100's

CENTER

SWITCH10's

RIGHT

SWITCH1's

SAE No. 1Flywheel

118 teeth "1" "1" "8"

SAE No. 0Flywheel

142 teeth "1" "4" "2"

SAE No. 00Flywheel

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. Thetests are conducted by individually "misadjusting" the alarm set-points to simulatean alarm condition and observing the alarm annunciator response. Unlessotherwise noted the test settings are made at the Engine Room Panel using a1/16 inch Allen wrench at the adjustment point on the face of the gauge.



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

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

1. With system power on, engine

Alarm Annunciator Lights

not running

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

; set the LOCAL/REMOTE switch inREMOTE position.

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

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


Engine Coolant Alarm (Coolant Level Low)

not running

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.

, turn the Alarm Test Knob, locatedat the right side of the indicator glass, counter-clockwise until the indicatorcontacts and trips the low-level indicator switch.

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


Engine Coolant Alarm (Coolant Temperature High)

not running

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

, note the initial setting of the alarmcontact in the Engine Room Panel gauge; then move the alarm contact until it just touches the indicator needle.

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

not running, note the original setting of thealarm contact in the Engine Room Panel gauge then move the alarm contactuntil it just touches the indicator needle.



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2. The “WARNING” lamp on the Engine Room Panel should light, and the“ENGINE CRANKCASE PRESSURE” lamp on the Pilot House Panelannunciator should light.

3. After verifying alarm operation, move the alarm contact back to the originalposition

. The “WARNING” lamp and the “ENGINE CRANKCASE

PRESSURE” lamp should extinguish.

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

Engine Oil Pressure Alarm - Low Engine Speed Operation

2. With the engine running at idle speed, note the original setting

3. The “WARNING” lamp on the Engine Room Panel should light, and the

“ENGINE OIL PRESSURE” lamp should be lit on the pilothouse annunciator.

of the alarmcontact in the Engine Room Panel gauge then move the alarm contact until it just touches the indicator needle.

4. After verifying engine oil pressure alarm operation, move the alarm contactback to the original position

. The “WARNING” lamp and the “ENGINE OILPRESSURE” lamp should go out.

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

Engine Oil Pressure Alarm - Normal Engine Speed Operation

2. To temporarily deactivate the Marine Gear pressure alarm, note the originalsetting of the Marine Gear

3. Open the panel to access the speed switch, and turn the speed switchpotentiometer

gauge contact, then use a 1/16” Allen wrench to

move the contact well away from (below) the indicator needle.

clockwise

4. At this point,

until the “SPEED ADJ .” LED indicator turns on. (Seeprevious Speed Switch adjustment instructions for speed switch location andcontrol identification.)

if the engine oil pressure is below 159 kPa (23 psi)

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

, the“WARNING” lamp on the Engine Room Panel should light, and the “ENGINEOIL PRESSURE” lamp should light on the pilothouse annunciator.

1. Move the contact in the

Marine Gear Oil Pressure Alarm

marine gear oil pressure gauge back to the original

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

gauge contact setting. This adjustment will make contact with the alarmswitch and activate the alarm.



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

Engine Speed Switch - Reset

With the engine running at the set-point speed, turn the Speed Switch,SPEED ADJ . potentiometer screw counterclockwise

When the speed switch is reset to the previous switch point speed the“ENGINE OIL PRESSURE” and “GEAR OIL PRESSURE” alarm indicatorsshould be extinguished.

until the PICKUP LEDlight comes on. Refer to the previous Speed Switch adjustment procedure.

References

Unless otherwise noted, documents referenced in this bulletin may be acquired

at http://marine.cummins.com.

Change Log

Date Change PageRevising Author’s

Name

11/09/2005 No content change/Uploaded to web site DDC07/15/2008 Updated Web url for reference documents 29 ddc07/14/2009 Extended expiration date CS

07/15/2009 Corrected font size/Published to the web CS07/13/2010 Extended expiration date CS

Distribution of this document is intended for Cummins personnel and distributors. The information contained in thisdocument is only considered valid while published on the Marine Website. Copies and archived documents are notconsidered current.

http://marine.cummins.com/




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