Page 1
INSTALLATION
MANUAL
MCGBA, MCGCA, MCGCB,
MCGGA, MCGDA, MCGDB
Printed in U.S.A. 960-0613 7-91
Page 2
Safety Precautions
Before operating the generator set, read the Operator’s
Manual and become familiar with it and your unit. Safe and ef-
ficient operation can be achieved only if the unit is properly
operated and maintained. Many accidents are caused by fail-
ure to follow fundamental rules and precautions.
Throughout this manual you will notice symbols which alert you
to potentially dangerous conditions to the operator, service personnel, or the equipment itself.
This symbol warns of immediate hazards which will result in severe personal injury or
death.
This symbol refers to a hazard or unsafe
practice which can result in severe personal injury or
death.
This symbol refers to a hazard or unsafe
practice which can result in personal injury or product or property damage.
FUEL, ENGINE OIL, AND FUMES ARE FLAMMABLE AND
TOXIC. Fire, explosion, and personal injury can result from im-
proper practices.
• Benzene and lead, found in some gasoline, have been
identified by some state and federal agencies as causing
cancer or reproductive toxicity. When checking, draining
or adding gasoline, take care not to ingest, breathe the
fumes, or contact gasoline.
• Used engine oils have been identified by some state or
federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to
ingest, breathe the fumes, or contact used oil.
• Do not fill fuel tanks with the engine running. Do not smoke
around the generator set area. Wipe up any oil or gas
spills. Do not leave oily rags in engine compartment or on
the generator set. Keep this and surrounding area clean.
• Inspect fuel system before each operation and periodically
while running.
• Equip the engine fuel supply with a positive fuel shutoff.
EXHAUST GASES ARE DEADLY
• Provide adequate ventilation. Equip the bilge with a power
exhauster.
• Be sure propulsion and generator set engine exhaust sys-
tems are free of leaks. Perform thorough, periodic inspections of the exhaust system and repair leaks immediately.
Exhaust gases are deadly.
• Never sleep in the vessel with the generator set running
unless the vessel is equipped with an operating carbon
monoxide detector.
HOT COOLANT CAN CAUSE SEVERE PERSONAL
INJURY
• Hot coolant is under pressure. Do not loosen the coolant
pressure cap while the engine is hot. Let the engine cool
before opening the pressure cap.
MOVING PARTS CAN CAUSE SEVERE PERSONAL
INJURY OR DEATH
• Do not remove any belt guards or covers with the genera-
tor set running.
• Keep hands and loose clothing away from moving parts.
Do not wear jewelry while servicing any part of the generator set.
• Never step on the generator set (as when entering or leav-
ing the engine compartment). It can stress and break unit
components, possible resulting in dangerous operating
conditions. . . from leaking fuel, leaking exhaust fumes,
etc.
• Before performing any maintenance on the generator set,
disconnect its batteries to prevent accidental starting. do
not disconnect or connect battery cables if fuel vapors are
present. Ventilate the generator set compartment or bilge
thoroughly with the power exhauster.
ELECTRICAL SHOCK WILL CAUSE SEVERE
PERSONAL INJURY OR DEATH
• Do not make adjustments in the control panel or on engine
with unit running. High voltages are present. Work that
must be done while unit is running should be done only by
qualified service personnel standing on dry surfaces to reduce shock hazard.
• Always disconnect the battery ground (−) lead first and re-
connect it last. Make sure you connect the battery correctly. A direct short across the battery terminals can cause an
explosion. Do not smoke while servicing batteries. Hydrogen gas given off during charging is very explosive.
• Keep a fire extinguisher available in or near the engine
compartment and in other areas throughout the vessel.
Use the correct extinguisher for the area. For most types
of fires, an extinguisher rated ABC by the NFPA is available and suitable for use on all types of fires except alcohol.
Copy and post these suggestions in potential hazard areas of the vessel.
• DO NOT CONNECT THE GENERATOR SET TO THE
PUBLIC UTILITY OR TO ANY OTHER ELECTRICAL
POWER SYSTEM. Electrocution or damage to property
can occur at a site remote from the boat where line or
equipment repairs are being made if the set is connected
to the power system. An approved transfer switch must be
used if more than one power source is to be made available to service the boat.
• Do not work on this equipment when mentally or physically
fatigued, or after consuming any alcohol or drug that
makes the operation of equipment unsafe.
Page 3
Table of Contents
SECTION TITLE PAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY PRECAUTIONS Inside Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 INTRODUCTION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standards for Safety 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 LOCATION AND MOUNTING 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting 2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 ENGINE COOLING SYSTEM 3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 VENTILATION 4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 EXHAUST SYSTEM 5-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 FUEL SUPPLY SYSTEM 6-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 AC CONNECTIONS 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transfer Switch 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connections 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 7-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 DC CONNECTIONS 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Connections 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Connections 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Grounding 8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 STARTUP 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filling Engine Oil and Coolant 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Priming The Turbocharger 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starting 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine Gauges 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Frequency 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Output Voltage 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Check List 9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 SPECIFICATIONS 10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
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Section 1. Introduction
GENERAL
A generator set must be installed properly if you are to expect safe, reliable and quiet operation. Read through this
manual completely before starting the installation. It is a
guide only . You must decide how to address the considerations peculiar to your installation.
Decisions you have to make will concern:
• Location and Mounting of the set
• Engine exhaust discharge and silencing
• Engine cooling
• Engine room ventilation
• Fuel connections
• Starting batteries
• Electrical connections
• Bonding for grounding
• Accessibility for operation and maintenance
• Attenuation of noise and vibration.
Refer to Operator’s Manual 960-0148 regarding operation and maintenance.
STANDARDS FOR SAFETY
It is suggested that you obtain the following standards if
you build for the U.S. domestic market:
“Standards and Recommended Practices For Small
•
Craft”
American Boat and Yacht Council, Inc.
P.O. Box 747
Millersville, MD 21108
• NFPA No. 302,
Craft”
National Fire Protection Association
• USCG regulations are found under Titles 33 and 46
of the Code of Federal Regulations (CFR).
U.S. Government Printing Office
“Pleasure and Commercial Motor
Batterymarch Park
Quincy, MA 02269
Washington, D.C. 20404.
Y ou must find out which standards for safety are applicable to the installation. The American Boat and Yacht
Council (ABYC) and the National Fire Protection Association (NFPA) are typical of agencies that publish safety
standards for the installation of marine equipment. The
United States Coast Guard (USCG) is a typical regulatory agency.
Improper installation can lead to severe
personal injury or loss of life and property by fire,
electrocution, mechanical breakdown or exhaust
gas asphyxiation. You must be qualified to install
marine generator sets, having knowledge of fuel,
electrical and machinery hazards.
1-1
Page 5
GOVERNOR
ACTUATOR
FUEL INJECTION
PUMP UNIT
FUEL
FILTER
AIR
CLEANER
RESETTABLE FAULT
SHUTDOWN CIRCUIT
BREAKER
STANDARD FOUR
GAUGE ENGINE
CONTROL PANEL
M1895s
START/RUN/STOP
SWITCH
AC POWER OUTPUT
BOX AND GENERATOR
SEA WATER
INLET AT
PUMP
EXHAUST OUTLET
OIL
DIPSTICK
(WET ELBOW)
OIL
FILL
FUEL INLET
AND OUTLET
FITTINGS
HEAT
EXCHANGER
FUEL LIFT
PUMP WITH
PRIMING LEVER
OIL FILTER
(OPTIONAL
LOCATION)
COOLANT EXPANSION TANK
AND PRESSURE CAP
OPTIONAL FUEL
FILTER AND WATER
SEPARATOR
ELECTRONIC
GOVERNOR
CONTROL
VIBRATION
ISOLATOR
(ONE OF
FOUR)
SKID
STARTER
MOTOR
NORMAL LOCATION OF
OIL FILTER
FIGURE 1-1. TYPICAL GENERATOR SET
1-2
BATTERY CHARGING
ALTERNATOR
M1894s
LOCATION OF ENGINE
COOLANT PUMP
Page 6
Section 2. Location and Mounting
Draw up plans for location and mounting on the basis of
the applicable outline drawing of the set. See your distributor.
LOCATION
Locate the set where there will be enough room to perform periodic maintenance and service. Because of
noise, vibration and fumes, the generator room should be
located as far from living quarters as possible. The requirements for ventilation, engine cooling and exhaust
discharge must also be considered when locating the set.
The set is equipped with a single lifting eye for lowering it
into the vessel. If the set has a sound shield, remove the
cover in the top of the cabinet for access to the lifting eye.
Do not install these generator sets in
conjunction with gasoline fueled equipment. They
are not “ignition protected” and can therefore ignite
gasoline fumes.
MOUNTING
The set should be mounted as level as possible. The skid
can usually be bolted directly to the hull frame members
when integral vibration isolators are provided between
the engine/generator assembly and the skid.
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Page 7
Section 3. Engine Cooling System
Figure 3-1 is a schematic of a typical cooling system. Liquid coolant is pumped through passages in the cylinder
block, head, exhaust manifold and turbocharger housing. A liquid-to-liquid heat exchanger and an expansion
tank with a pressure cap (15 psi) are mounted on the engine. Coolant is pumped through the engine - heat exchanger circuit by the engine coolant pump. Sea water
(the flotation water) is pumped through the heat exchanger by a second engine-driven pump. Cathodic
protection of all sea water wetted metal parts of the heat
exchanger system is provided by a replaceable zinc plug
in the heat exchanger.
Locate the set within the 6 foot (1.7 M) lifting capability of
the sea water pump. The sea water intake fitting and sea
cock should be as close to the engine as possible and
provide positive water intake under all operating conditions.
SEA WATER
HULL INLET
FITTING
A sea water strainer must be provided to remove debris
larger than 0.06 inches (1.6 mm) to protect the pump and
reduce heat exchanger fouling.
There should be as few bends in the piping as possible.
However, t o maintain prime when the set is not in use, it is
recommended that the piping loop between the sea water pump and the strainer, to create a water trap. The
pump must be primed before startup. See
Startup
The sea water pump has a neoprene impeller that can disintegrate in a matter of seconds after the engine starts if pump prime has been lost.
Use approved flexible hose to connect the engine and
piping to take up movement of the set.
The sea water is discharged through the wet exhaust
SEA
COCK
system. See
Exhaust System
for connections.
SEA WATER
STRAINER
.
SEA WATER OUTLET HOSE FROM HEAT EX−
CHANGERSEE EXHAUST SYSTEM FOR
CONNECTIONS
FIGURE 3-1. SCHEMATIC OF A TYPICAL COOLING SYSTEM
TOP VIEW OF SET
HEAT
EXCHANGER
SEA
WATER
PUMP
EXPANSION
TANK
CS1391
3-1
Page 8
Section 4. Ventilation
Generator set compartment air temperature must not exceed 122° F (50° C). Higher temperatures will result in
overheating of the generator windings, tripping of circuit
breakers and loss of engine power . Ventilation is also required to prevent dangerous concentrations of fuel vapors and exhaust fumes.
Coast Guard requirements for minimum ventilation in
passenger vessels are summarized in Table 4-1.
TABLE 4-1. USCG REGULATIONS FOR
VENTILATION OF EQUIPMENT ROOMS IN
PASSENGER VESSELS
SIZE OF MAXIMUM TIME ALLOWED
COMPARTMENT TO EXCHANGE TOTAL
Cu. Ft. (m
Less than 500 (14) 2. . . . . . . . . . . . . . . . . . . .
500 to 1000 (14 to 28) 3. . . . . . . . . . . . . . . . . .
1000 to 1500 (28 to 42) 4. . . . . . . . . . . . . . . . . .
1500 and Up (42 and Up) 5. . . . . . . . . . . . . . . . .
3
) AIR VOLUME (MINUTES)
It should be noted that air flow required for preventing excessive generator compartment air temperature will usually be greater than that required for meeting USCG requirements for evacuating vapors and fumes.
For best results, fresh air should enter near the bottom of
the generator set compartment, at the generator end.
Warm compartment air should exit near the top, at the
other end of the compartment.
See the applicable Specification Sheet for data necessary for ventilating air flow calculations. Application
Manual T-030 has example air flow calculations.
Carbon monoxide (CO) detectors, listed for marine applications, should be installed in the living quarters of the
vessel. Wind shifts, boat motion, exhaust from other
boats at dockside, etc. can cause exposure to harmful
concentrations of carbon monoxide even when proper
ventilation is provided and living quarters are separated
from machinery compartments.
4-1
Page 9
Section 5. Exhaust System
These sets have a “wet elbow” for a wet exhaust system.
The full flow of sea water that is pumped through the heat
exchanger passes through the wet elbow into the exhaust gas stream. The sea water is thereby discharged to
the outside along with the exhaust gas through the exhaust hull fitting. The water cools the exhaust gas enough
so that rubber hose can be connected directly to the wet
elbow. (The exhaust system is protected in the event of a
pump failure, blockage or other such event by a high exhaust temperature shutdown switch). The wet elbow is
adjustable to point down between 30 and 90 degrees.
Figure 5-1 shows typical wet exhaust systems.
Engine exhaust includes deadly carbon
monoxide gas (CO). The exhaust system must be
gas tight and discharge all engine exhaust outside.
The exhaust hull fitting must always be located above the
load water line. The transom is the preferred location,
where water is less likely to enter because of waves and
vessel roll. The exhaust fitting must also be aft of all other
openings to reduce the likelihood of recirculating exhaust
gas through the other openings.
Where at all possible, it is recommended that the set be
located so that the outlet of the turbocharger is at least 12
inches (305 mm) above the load water line. A blind tee
should then be connected to the wet elbow to prevent water from backing up into the turbocharger. Exhaust piping
should have as few bends as possible and slope down
from the engine at least 1/2 inch per foot (2 degrees).
There should be enough support so that the piping does
not sag or dip.
If the set must be located so that the outlet of the wet elbow is less than 12 inches (305 mm) above the load water line, it will be necessary to provide a water lift muffler
below the exhaust outlet and an anti-siphon break at
least 12 inches (305 mm) above the load water line.
Use approved hose, piping, fittings, clamps and muffler.
Rubber exhaust hose must be Certified for marine use.
To facilitate hose connections and to take up engine
movement, there should be a gap of one pipe diameter
between the end of the rigid exhaust piping and the engine exhaust outlet. Double clamp each hose connection. The entire exhaust system must be accessible for inspection and repair.
Exhaust back pressure must not exceed 41 inches WC
(10.2 kPa). See the applicable Specification Sheet for
data necessary for exhaust back pressure calculations.
Application Manual T-030 has example dry exhaust back
pressure calculations. Wet exhaust back pressure tends
to be higher than dry exhaust back pressure because of
the extra water and steam. The calculated value, based
on dry exhaust, should therefore be doubled to obtain the
wet exhaust back pressure. It should be noted that water
lift mufflers impose high exhaust back pressure.
Excessive exhaust back pressure reduces the air-fuel ratio - resulting in reduced power ,
smoke, high exhaust temperature and reduced engine life.
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Page 10
INSTALLATIONS ABOVE LOAD WATER LINE
TURBOCHARGER
WET ELBOW
RUBBER HOSE SECURED
BY TWO CLAMPS EACH
END
HEAT EXCHANGER TO WET
ELBOW CROSSOVER HOSE
HEAT
EXCHANGER
TRANSOM
TRANSOM
MUFFLER
BLIND
TEE
LOAD WATER
LINE
INSTALLATIONS BELOW LOAD WATER LINE
ANTI−SIPHON VALVE
RECONNECT AS SHOWN
1/2 INCH PER FOOT
(2 DEGREES) MINIMUM
SLOPE
12 INCHES (305 mm)
MINIMUM
REMOVE THE CROSSOVER HOSE FROM THE
HEAT EXCHANGER TO THE WET ELBOW AND
12 INCHES (305 mm)
1/2 INCH PER FOOT
(2 DEGREES) MINIMUM
SLOPE
12 INCHES (305 mm)
MINIMUM
MINIMUM
WET
ELBOW
EXS1183
LOAD WATER
LINE
48 INCHES (1.2 m)
MAXIMUM
FIGURE 5-1. TYPICAL WET EXHAUST SYSTEMS
5-2
12 INCHES (305 mm)
MINIMUM
WATER LIFT
MUFFLER
HEAT
EXCHANGER
EXS1183-1
Page 11
Section 6. Fuel Supply System
These generator sets are rated utilizing ASTM No. 2 diesel fuel. Check the engine Operation Manual for the
range of acceptable fuels.
Diesel fuel is highly combustible. The
fuel supply system must not leak. The installation,
inspection and testing of the fuel supply system
must be done by qualified persons in accordance
with applicable regulations.
There must be access for priming the engine-mounted
fuel lift pump on the left side of the engine (looking from
the alternator end).
An approved fuel / water separator must be installed
ahead of the engine fuel lift pump since the lift pump as
well as fuel injection pump can be damaged by water. A
fuel / water separator kit that mounts on the flywheel
housing is available from your distributor.
Failure to provide an approved fuel/water separator and filter upstream of the enginemounted fuel lift pump can lead to pump and injection unit failures and consequent disabling of the
set.
A skid mounted plate on the fuel pump side of the engine
carries 1/4 - 18 NPTF fuel supply and return fittings. Rigid fuel lines may be connected to these fuel fittings only if
the skid is rigidly secured to the hull frame members.
USCG Type A1 nonmetallic fuel hose or equivalent
should be used for supply and return connections to take
up movement of the set when the skid is mounted on external vibration isolators. The hose should be nonmetallic
to prevent accidental passage of cranking current, which
can melt metal wire braided hose, causing leakage and
possible fire.
The fuel supply tank may be connected directly if the bottom is not more than 5 feet (1.5 M) below the engine fuel
lift pump or the top more than 6 feet (1.8 M) above the fuel
injectors. The fuel return line must be run to the bottom of
the tank to prevent the system from draining back.
A fuel transfer pump and auxiliary tank will be necessary
if the bottom of the supply tank is more than 5 feet (1.5 M)
below the engine fuel lift pump.
An auxiliary tank with float valve will be necessary if the
top of the supply tank is more than 6 feet (1.8 M) above
the fuel injectors. A fuel strainer must be installed to protect the float valve seat from debris that could cause it to
leak.
Fuel tank construction, location, installation,venting, piping, inspection and testing must comply with applicable
regulations.
Do not use galvanized fuel tanks, fittings or pipes. Diesel fuel has sulfur residue that attacks the galvanized (zinc) coating, causing debris
that can clog fuel filters and pumps.
6-1
Page 12
Section 7. AC Connections
The AC power supply system must be installed and inspected in accordance with the applicable regulations.
Improper power supply wiring can
cause fire and electrocution, resulting in severe personal injury or death.
TRANSFER SWITCH
Use an approved transfer switch if provision is made for
connecting shore power.
Interconnecting the generator set with
shore power can cause dangerous transient voltages, damage to the generator set and electrocution,
resulting in severe personal injury or death.
CONNECTIONS
Flexible conduit and stranded conductors must be used
for connections to take up movement of the set.
Most models have 12 leads and a terminal block to reconnect the generator to provide the voltages required for the
installation. See Figure 7-1. Reconnections may require
rerouting the leads through current transformers CT 21,
CT 22 and CT 23 (if provided) and change of line circuit
breaker (if provided).
The loads must be balanced within ten percent of the average phase load in three phase power systems.
A 20 foot (6 M) long plug-in extension harness is available so that the AC meter panel (if provided) can be
mounted at a convenient location in the generator room.
GROUNDING
The generator set, power supply wiring and all connected
electrical utilizing equipment must be bonded to the common bonding conductor of the vessel in accordance with
the applicable regulations.
Faulty bonding for grounding can
cause fire and electrocution, resulting in severe personal injury or death.
7-1
Page 13
625-216
4
FIGURE 7-1. AC RECONNECTION DIAGRAM
7-2
Page 14
Section 8. DC Connections
These sets have either a 12 VDC or a 24 VDC system for
cranking and engine control. The system has either a
negative ground or an isolated ground. Check the nameplate.
BATTERY CONNECTIONS
See
Specifications
amp rating. Mount the batteries in accordance with regulations as close as possible to the set.
The battery cables must be sized so that voltage drop between the batteries and the starter motor is not more that
2 volts for 24 volt systems and 1 volt for 12 volt systems.
Application Manual T-030 has example battery cable sizing calculations.
Figure 8-1 illustrates how to connect two 12 volt batteries
for 24 volt systems. The negative battery cable should be
secured to the starter, as shown, or to the engine block.
Remove any paint, rust or grease under the connector so
that it will touch bare metal.
To prevent accidental starting, the last step in the installation should be to connect the negative (-) battery cable to
the engine.
while working on it can cause severe personal injury
or death. Prevent accidental starting by disconnecting the starting battery cables (negative (-) first).
Always disconnect the negative (-) battery cable
first, and reconnect it last, to prevent arcing if a tool
accidentally touches the frame or other grounded
metal part while disconnecting or reconnecting the
positive (+) battery cable. Arcing can ignite the explosive gas given off by batteries, causing severe
personal injury.
Do not smoke near batteries. A cigarette can ignite
the hydrogen gas given off by batteries.
for the required battery cold cranking
Accidental starting of the generator set
REMOTE CONTROL CONNECTIONS
A 20 foot (6 M) long plug-in extension harness is available so that the engine control panel can be mounted at a
convenient location in the generator room. A pilot house
control panel with 20 foot (6M) plug-in extension harness
is also available.
STARTER
SOLENOID
NEGATIVE
CONNECTION
AT STARTER
MOUNTING
BOLT OR
ENGINE
BLOCK
FIGURE 8-1. BATTERY CONNECTIONS FOR 24 VOLT, NEGATIVE
GROUND SYSTEMS
12 V BATTERY
−
12 V BATTERY
−
POSITIVE
CONNECTION
+
+
STARTER
MOTOR
ES1693
GROUNDING
Check the applicable regulations to determine whether
the negative battery terminal should be bonded to the
common bonding conductor of the vessel or be isolated.
A kit is available, if necessary, to convert the engine control system for isolated battery grounding.
8-1
Page 15
Section 9. Startup
Read Operator’s Manual 960-0148 before startup, and
observe all the instructions and precautions.
FILLING ENGINE OIL AND COOLANT
The engine must be filled with oil and coolant before starting. If the set is heat exchanger-cooled, prime the sea
water pump. See
for instructions on how to fill engine oil and coolant and
prime the sea water pump.
run without oil or coolant.
Maintenance
The engine will be severely damaged if
in the Operator’s Manual
PRIMING THE TURBOCHARGER
When the engine is equipped with a turbocharger, disconnect the oil supply line at the turbocharger housing
and fill the bearing with engine oil. Reconnect the oil line.
DISCONNECT THE
OIL SUPPLY LINE
AT THIS POINT TO
PRIME THE
TURBOCHARGER
The fuel injection system is self venting and will probably
not need to be bled. See the engine
it is necessary to bleed the fuel injection system.
Operation Manual if
STARTING
Hold the control panel switch in the START position. Release the switch when the engine starts. (The starter will
disengage automatically when the engine starts up.) See
Troubleshooting
does not start, or starts but does not continue to run.
starter motor and cause it to fail. Do not crank the engine for more than 30 seconds at a time. Wait two
minutes before trying again.
in the Operator’s Manual if the engine
Excessive cranking can overheat the
ENGINE GAUGES
Check the engine gauges while the engine is running.
Oil Pressure Gauge
Engine oil pressure should be between 35 and 60 psi
when the engine is at normal operating temperature.
Coolant Temperature Gauge
LS1167
FIGURE 9-1. PRIMING THE TURBOCHARGER BEARING
FUEL
See
Maintenance
tions on how to bleed air from the fuel supply line and filters.
in the Operator’s Manual for instruc-
Engine coolant temperature should be between 170°F
and 210°F during normal operation.
DC Voltmeter
Battery charging voltage should be between 24 and 28
volts for 24 volt systems and 12 and 14 volts for 12 volt
systems.
OUTPUT FREQUENCY
See the Operator’s Manual for checking and adjusting
output frequency.
OUTPUT VOLTAGE
See the Operator’s Manual for checking and adjusting
output voltage.
INSTALLATION CHECK LIST
Before putting the set into service, check each of the following areas while the set is running under load.
Mechanical
Check for loose mounting bolts, damaged components
and interference with bulkheads or other equipment.
9-1
Page 16
Lubrication
Check for oil leaks. When the engine has been stopped
for at least ten minutes, check the oil level.
and bilge with fuel. The installation, inspection and
testing of the fuel supply system must be done by
qualified persons in accordance with applicable regulations.
Cooling
Check for coolant leaks. When the engine has cooled
down, check the coolant level.
To prevent severe scalding, always let
the engine cool down before removing the coolant
pressure cap. Turn the cap slowly, and do not open it
fully until the pressure has been relieved.
Fuel
Check for leaks in all fuel lines, fittings, filters and tanks.
Check for cuts, abrasions and rubbing in flexible fuel
lines.
Diesel fuel is highly combustible. The
fuel supply system must not leak and must have
safeguards to prevent accidental flooding of engine
Control
Start and run the set several times from the local control
panel. Also start and run the set from the pilot house control panel, if provided.
Wiring
Check all line, control, battery and grounding connections.
Exhaust
Check the entire exhaust system by looking and listening
for leaks.
Engine exhaust includes deadly carbon
monoxide gas (CO). The exhaust system must be
gas tight and discharge all engine exhaust outside.
9-2
Page 17
Section 10. Specifications
MODEL NUMBER MCGBA MCGCA MCGCB MCGGA MCGDA MCGDB
FUEL No. 2 No. 2 No. 2 No. 2 No. 2 No. 2
SPECIFICATION Diesel Diesel Diesel Diesel Diesel Diesel
FUEL SUPPLY AND 1/4-18 1/4-18 1/4-18 1/4-18 1/4-18 1/4-18
RETURN FITTINGS NPTF NPTF NPTF NPTF NPTF NPTF
ENGINE OIL 11.5 qts. 11.5 qts. 11.5 qts. 16 qts. 16 qts. 16 qts.
CAPACITY (11L) (11 L) (11 L) (15 L) (15 L) (15 L)
BATTERY
VOLTAGE* 12 or 24 12 or 24 12 or 24 12 or 24 12 or 24 12 or 24
RECOMMENDED
BATTERY RATING** 625 625 625 625 625 625
COOLANT CAPACITY 3.5 gal 3.5 gal 3.5 gal 5.4 gal 5.5 gal 5.5 gal
(H. E. and Engine) (13 L) (13 L) (13 L) (20 L) (21 L) (21 L)
WET EXHAUST 3-1/2 in. 3-1/2 in. 3-1/2 in. 3-1/2 in. 3-1/2 in. 3-1/2 in.
HOSE SIZE I.D. I.D. I.D. I.D. I.D. I.D.
SEA WATER 1-1/4 in. 1-1/4 in. 1-1/4 in. 1-1/4 in. 1-1/4 in. 1-1/4 in.
INLET HOSE SIZE I.D. I.D. I.D. I.D. I.D. I.D.
* - See Nameplate
** - SAE J537 cold cranking amps (CCA)
6-1
Page 18
Cummins Power Generation
1400 73rd Avenue N.E.
Minneapolis, MN 55432
763-574-5000
Fax: 763-528-7229
Cummins and Onan are registered trademarks of Cummins Inc.
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