Service Manual

Onan Generator Set for Marine

MDDCA (Spec A-C)

MDDCB (Spec A-C)
MDDCC (Spec A-C)
MDDCD (Spec A-C)
MDDCE (Spec A-C)
MDDCF (Spec A-C)
MDDCG (Spec A-C)
MDDCH (Spec A-C)
MDDCJ (Spec A-C)
MDDCK (Spec B-C)
MDDCL (Spec A)
MDDCM (Spec A)
MDDCN (Spec A)
MDDCP (Spec A)
MDDCR (Spec A)

English
Original Instructions 6-2018 0981-0539 (Issue 9)
Table of Contents
1. SAFETY PRECAUTIONS .............................................................................................................. 1
1.1 Overview ................................................................................................................................. 1
1.2 Precaution Symbols ................................................................................................................ 1
1.3 General Safety Precautions.................................................................................................... 2
1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death.................. 4
1.5 Generator Set Voltage Is Deadly ............................................................................................ 5
1.6 Engine Exhaust Is Deadly....................................................................................................... 5
1.7 Diesel Fuel Is Combustible ..................................................................................................... 6
1.8 Battery Gas Is Explosive......................................................................................................... 6
1.9 Moving Parts Can Cause Severe Personal Injury or Death ................................................... 6
1.10 Flammable Vapor Can Cause a Diesel Engine to Overspeed ............................................. 6
1.11 Hazards of Carbon Monoxide ............................................................................................... 7
1.11.1 Carbon Monoxide Poisoning...................................................................................... 7
1.11.2 Special Risks of CO on Boats.................................................................................... 7
1.11.3 Protection from CO Poisoning ................................................................................... 8
1.12 Substances Hazardous to Health ......................................................................................... 8
1.12.1 Antifreeze (Fleetguard - ES Compleat and EG Premix) ............................................ 8
1.12.2 Gas Oil ..................................................................................................................... 10
1.12.3 Lubricant Oil - Premium Blue E 15W40 ................................................................... 11
1.13 Generator Set Warning Labels ........................................................................................... 12

2. INTRODUCTION.......................................................................................................................... 15
2.1 About This Manual................................................................................................................ 15
2.1.1 Warning - Generator Set Not Ignition Protected ........................................................ 15
2.2 Related Literature ................................................................................................................. 16
2.3 Model Identification ............................................................................................................... 16
2.3.1 Nameplate Location ................................................................................................... 17
2.4 Emissions Label.................................................................................................................... 17
2.4.1 Emission Label Location ............................................................................................ 18
2.5 Noise..................................................................................................................................... 18
2.6 Electromagnetic Compatibility Compliance........................................................................... 19
2.7 Build Standards..................................................................................................................... 19

3. MAINTENANCE ........................................................................................................................... 21
3.1 Periodic Maintenance ........................................................................................................... 21
3.1.1 Periodic Maintenance Schedule ................................................................................ 21
3.2 General Inspection................................................................................................................ 22
3.2.1 Service Point Locations ............................................................................................. 23
3.2.2 Battery Connections................................................................................................... 25
3.2.3 Oil Level .................................................................................................................... 25
3.2.4 Fuel System Leaks .................................................................................................... 26
3.2.5 Coolant Level ............................................................................................................. 26

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3.2.6 Raw Water System .................................................................................................... 27

3.2.7 Exhaust System ......................................................................................................... 27
3.2.8 Mechanical System .................................................................................................... 27
3.3 Maintaining the Battery ......................................................................................................... 28
3.4 Maintaining the Lubrication System...................................................................................... 28
3.4.1 Oil Recommendations................................................................................................ 28
3.4.2 Changing Engine Oil and Filter.................................................................................. 29
3.5 Maintaining the Fuel System ................................................................................................ 31
3.5.1 Fuel Recommendations ............................................................................................. 31
3.5.2 Draining the Fuel Filter............................................................................................... 33
3.5.3 Replacing Fuel Filter .................................................................................................. 33
3.5.4 Priming the Fuel System............................................................................................ 35
3.6 Maintaining the Cooling System ........................................................................................... 38
3.6.1 Cooling System Components .................................................................................... 39
3.6.2 Pressure Cap ............................................................................................................. 39
3.6.3 Coolant Hoses............................................................................................................ 40
3.6.4 Siphon Break.............................................................................................................. 40
3.6.5 Coolant Recommendations........................................................................................ 41
3.6.6 Replenishing Normal Coolant Loss............................................................................ 42
3.6.7 Refilling the Cooling System ...................................................................................... 42
3.6.8 Draining and Cleaning Cooling System ..................................................................... 43
3.6.9 Heat Exchanger ......................................................................................................... 44
3.6.10 Removing and Installing the Heat Exchanger.......................................................... 45
3.6.11 Draining and Cleaning the Heat Exchanger ............................................................ 46
3.6.12 Zinc Anode............................................................................................................... 46
3.6.13 Replacing the Thermostats ...................................................................................... 46
3.6.14 Replacing Raw Water Pump Impeller...................................................................... 48
3.6.15 Replacing the Serpentine Belt ................................................................................. 50
3.6.16 Disconnecting PTO Shaft......................................................................................... 51
3.7 Replacing the Air Filter Element ........................................................................................... 52
3.8 Replacing the CCV Filter Element ........................................................................................ 53
3.9 Storing the Generator Set..................................................................................................... 54
3.10 Cold Temperature Storage ................................................................................................. 54
3.11 Returning the Generator Set to Service ............................................................................. 55

4. GENERATOR SET CONTROL.................................................................................................... 57

4.1 Overview ............................................................................................................................... 57
4.2 Controller .............................................................................................................................. 57
4.2.1 Major Functions of Generator Set Controller ............................................................. 57
4.2.2 Control Block Diagram ............................................................................................... 59
4.2.3 Connectors................................................................................................................. 60
4.2.4 Generator Controller Mounting .................................................................................. 60
4.2.5 Configuring Generator Set Controller Using Digital Display ...................................... 60
4.2.6 Configuring Generator Set Controller Using Control Switch...................................... 61
4.2.7 Single or Parallel Generator Set Operation Switch.................................................... 62
4.2.8 Manual Voltage Control ............................................................................................. 62

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4.3 Control Box ........................................................................................................................... 62

4.4 Control Switch Schematic ..................................................................................................... 63
4.5 Control Relays ...................................................................................................................... 64
4.6 Master Hour Meter (M11) ..................................................................................................... 64
4.6.1 Master Hour Meter (M11)........................................................................................... 65
4.7 Emergency Stop Switch/Circuit Breaker............................................................................... 65
4.8 Network Interface Module (NIM)........................................................................................... 65
4.8.1 NIM Mounting Location .............................................................................................. 66
4.8.2 NIM Configuration Jumpers ....................................................................................... 66
4.8.3 Troubleshooting LEDs................................................................................................ 67
4.8.4 Troubleshooting Network ........................................................................................... 68

5. ENGINE AND ACCESSORIES.................................................................................................... 69

5.1 Major Engine Service............................................................................................................ 69
5.2 ECM and Engine Sensors .................................................................................................... 69
5.3 High Exhaust Temperature Switch (S5) ............................................................................... 70
5.3.1 High Exhaust Temperature Switch ............................................................................ 71
5.4 Low Coolant Level Switch (S3)............................................................................................. 71
5.4.1 Low Coolant Level Switch (S3).................................................................................. 72
5.5 Raw Water Flow Switch (S6) ................................................................................................ 72
5.5.1 Raw Water Flow Switch (S6) ..................................................................................... 73
5.6 Low/High Oil Level Gauge .................................................................................................... 73
5.7 Starter and Start Solenoid ................................................................................................... 74
5.8 Battery Charging Alternator .................................................................................................. 75
5.9 Electric Fuel Pump................................................................................................................ 76
5.10 Mechanical Fuel Pump ....................................................................................................... 77
5.10.1 Vacuum/Pressure Tests........................................................................................... 77
5.10.2 Leakage Test ........................................................................................................... 78
5.10.3 Removing Pump....................................................................................................... 78
5.10.4 Installing Pump......................................................................................................... 78
5.11 Adjusting Valve Lash .......................................................................................................... 78
5.12 Replacing Fuel Injection Nozzles........................................................................................ 81
5.12.1 Removing Injection Nozzles .................................................................................... 81
5.12.2 Installing Injection Nozzles....................................................................................... 83
5.13 Coolant Pump ..................................................................................................................... 83
5.13.1 Removing Pump....................................................................................................... 83
5.13.2 Installing Pump......................................................................................................... 84
5.14 Auxiliary Drive ..................................................................................................................... 85
5.15 Raw Water Pump................................................................................................................ 85
5.16 Timing Gear Cover Gasket ................................................................................................. 86
5.16.1 Removing Timing Gear Cover ................................................................................. 86
5.16.2 Installing Timing Gear Cover and Gasket................................................................ 86
5.17 Oil Pan Gasket.................................................................................................................... 87
5.18 Oil Cooler ............................................................................................................................ 87
5.18.1 Removing the Oil Cooler.......................................................................................... 89
5.18.2 Installing the Oil Cooler............................................................................................ 89

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5.19 Front Crankshaft Oil Seal ................................................................................................... 90

5.19.1 Removing the Front Oil Seal.................................................................................... 90
5.19.2 Installing the Front Oil Seal...................................................................................... 92
5.20 Rear Crankshaft Oil Seal .................................................................................................... 93
5.20.1 Removing the Rear Oil Seal .................................................................................... 93
5.20.2 Installing the Rear Oil Seal ...................................................................................... 95
5.21 Generator Set Mounting...................................................................................................... 98
5.22 PTO Assembly .................................................................................................................... 99
5.22.1 Clutch Assembly ...................................................................................................... 99
5.22.2 PTO Bracket and Coupler...................................................................................... 100

6. ALTERNATOR ........................................................................................................................... 103

6.1 Overview ............................................................................................................................. 103
6.2 Faulty Generator or Regulator Testing ............................................................................... 103
6.3 Generator Stator and Rotor Winding Resistances ............................................................. 104
6.4 Exciter Stator ...................................................................................................................... 106
6.4.1 Winding Insulation Resistance................................................................................. 106
6.4.2 Winding Resistance ................................................................................................. 106
6.4.3 Exciter Stator Test ................................................................................................... 107
6.5 Exciter Rotor ....................................................................................................................... 107
6.5.1 Winding Insulation Resistance................................................................................. 107
6.5.2 Winding Resistance ................................................................................................. 107
6.5.3 Exciter Rotor ............................................................................................................ 108
6.6 Rotating Rectifiers............................................................................................................... 108
6.6.1 Diode Test................................................................................................................ 108
6.6.2 Diode Replacement.................................................................................................. 109
6.6.3 Surge Suppressors .................................................................................................. 109
6.6.4 Testing the Rotating Rectifier Assembly .................................................................. 110
6.7 Main Rotor .......................................................................................................................... 110
6.7.1 Winding Insulation Resistance................................................................................. 110
6.7.2 Winding Resistance ................................................................................................. 111
6.7.3 Testing the Main Rotor............................................................................................. 111
6.8 Main Stator.......................................................................................................................... 112
6.8.1 Winding Insulation Resistance................................................................................. 112
6.8.2 Winding Resistance ................................................................................................. 112
6.9 Generator Assembly ........................................................................................................... 113
6.10 Generator Disassembly .................................................................................................... 114
6.10.1 Air Baffle Removal ................................................................................................. 114
6.10.2 Removing the Generator Output Box .................................................................... 115
6.10.3 Removing the Generator........................................................................................ 116
6.10.4 Removing the Rotor ............................................................................................... 116
6.11 Generator Reassembly ..................................................................................................... 116
6.12 Servicing The PMG........................................................................................................... 117
6.12.1 Disassembling the PMG ........................................................................................ 117
6.12.2 Reassembling the PMG ......................................................................................... 118
6.12.3 PMG Assembly ...................................................................................................... 119

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7. ADJUSTING AC OUTPUT VOLTAGE ....................................................................................... 121

7.1 Adjusting Voltage ................................................................................................................ 121
7.2 Voltage Regulator - PMG Excited Generators.................................................................... 121
7.2.1 Automatic Voltage Regulator (AVR) ........................................................................ 121
7.2.2 Isolation Transformer T30........................................................................................ 122
7.2.3 Manual Voltage Regulator (Optional)....................................................................... 123
7.3 Adjusting Voltage - PMG Excited Generators .................................................................... 123
7.3.1 Adjusting Voltage Using Voltage Regulator Trimmer .............................................. 123
7.3.2 Adjusting Reactive Droop Compensation ................................................................ 124
7.3.3 Voltage Regulator on PMG-Excited Generators ...................................................... 125
7.4 Adjusting Voltage - Quad-Winding Excited Generators...................................................... 125
7.4.1 Adjusting Voltage Using Digital Display ................................................................... 125
7.4.2 Adjusting Voltage Using Control Switch .................................................................. 126

8. TROUBLESHOOTING ............................................................................................................... 127

8.1 Overview ............................................................................................................................. 127
8.2 Troubleshooting with Digital Display................................................................................... 127
8.2.1 Fault Code No. 16 and Engine Pre-Alarms ............................................................. 127
8.3 Troubleshooting with Status Lamp ..................................................................................... 128
8.4 Troubleshooting Generator Set Faults................................................................................ 128
8.4.1 No Code - No Response at Digital Display or Control Switch ................................. 129
8.4.2 No Code - Starter Engages and Disengages .......................................................... 129
8.4.3 No Code - Starting Batteries Do Not Maintain a Charge ......................................... 129
8.4.4 No Code - No AC Power When Generator Set Is Running ..................................... 130
8.4.5 Code No. 3 - Service Check .................................................................................... 130
8.4.6 Code No. 4 - Overcrank........................................................................................... 130
8.4.7 Code No. 5 - Warning Shutdown due to CO ........................................................... 131
8.4.8 Code No. 6 - Oil Level High or Low ......................................................................... 131
8.4.9 Code No. 7 - Loss of Raw Water Flow .................................................................... 131
8.4.10 Code No. 12 - High AC Voltage............................................................................. 131
8.4.11 Code No. 13 - Low AC Voltage.............................................................................. 131
8.4.12 Code No. 14 - High AC Frequency ........................................................................ 132
8.4.13 Code No. 15 - Low AC Frequency......................................................................... 132
8.4.14 Code No. 16 - Engine Fault ................................................................................... 132
8.4.15 Code No. 27 - Loss of AC Voltage Sense ............................................................. 132
8.4.16 Code No. 29 - High Battery Voltage ...................................................................... 133
8.4.17 Code No. 32 - Starting Fault .................................................................................. 133
8.4.18 Code No. 35 - Control Card Failure - EE............................................................... 133
8.4.19 Code No. 36 - Unknown Shutdown ....................................................................... 133
8.4.20 Code No. 37 - Invalid Generator Set Configuration............................................... 134
8.4.21 Code No. 43 - Control Card Failure - RAM............................................................ 134
8.4.22 Code No. 45 - Speed Sense Lost .......................................................................... 134
8.4.23 Code No. 46 - Generator Set Overload ................................................................. 134
8.4.24 Code No. 57 - Overprime....................................................................................... 135
8.4.25 Code No. 58 - High Exhaust Temperature ............................................................ 135
8.4.26 Code No. 59 - Low Coolant Level.......................................................................... 135

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8.4.27 Code No. 61 - External Shutdown ......................................................................... 135

8.4.28 Code No. 72 - Lost NIM Communications ............................................................. 135
8.5 Engine Fault Code #16 ....................................................................................................... 136
8.5.1 Code No. SPN: 1, FMI: 0 - Engine Fault, Above Normal ....................................... 136
8.5.2 Code No. SPN: 97, FMI: 0 - Water In Fuel Indicator, Above Normal ...................... 136
8.5.3 Code No. SPN: 100, FMI: 1 - Engine Oil Pressure, Below Normal ......................... 137
8.5.4 Code No. SPN: 105, FMI: 0 - Intake Manifold Air Temperature Signal Out of
Range ....................................................................................................................... 137
8.5.5 Code No. SPN: 110, FMI: 0 - Engine Coolant Temperature, Above Normal .......... 137
8.5.6 Code No. SPN: 157, FMI: 3 - Fuel Rail Pressure Signal Out of Range High ......... 137
8.5.7 Code No. SPN: 157, FMI: 4 - Fuel Rail Pressure Signal Out of Range Low ......... 138
8.5.8 Code No. SPN: 174, FMI: 00 - Fuel Temperature Very High .................................. 138
8.5.9 Code No. SPN: 190, FMI: 0 - Engine Speed, Above Normal .................................. 138
8.5.10 Code No. SPN: 611, FMI: 3 - Injector Shorted to Voltage Source ........................ 138
8.5.11 Code No. SPN: 611, FMI: 4 - Injector Shorted to Ground .................................... 139
8.5.12 Code No. SPN: 629, FMI: 13 - Controller #1, Out of Calib.................................... 139
8.5.13 Code No. SPN: 970, FMI: 31 - Auxiliary Engine Shutdown Switch ....................... 139
8.5.14 Code No. SPN: 1076, FMI: 3 - Fuel Injection Pump Valve, Volt. Out/Range ........ 139
8.5.15 Code No. SPN: 1076, FMI: 5 - Fuel Injection Pump Valve, Cur. Out/Range ........ 139
8.5.16 Code No. SPN: 1076, FMI: 6 - Fuel Injection Pump Valve, Cur. Out/Range ........ 140
8.5.17 Code No. SPN: 1076, FMI: 10 - Fuel Injection Pump Valve, Abnormal
Rt/Chg........................................................................................................................ 140
8.5.18 Code No. SPN: 1076, FMI: 13 - Fuel Injection Pump Valve, Out of Calib. ........... 140
8.5.19 Code No. SPN: 1109, FMI: 31 - Approaching Shutdown ...................................... 140
8.5.20 Code No. SPN: 1110, FMI: 31 - Engine Has Shut Down ...................................... 140
8.5.21 Code No. SPN: 1136, FMI: 0 - ECU Temperature Very High .............................. 140
8.5.22 Code No. SPN: 1569, FMI: 31 - Engine Torque Derate ........................................ 141
8.5.23 Code No. SPN:2000, FMI: 06 - ECU Failure, Cur. Out/Range.............................. 141
8.6 Troubleshooting Engine Pre-Alarms ................................................................................... 141
8.6.1 Code No. SPN: 97, FMI: 16 - Water In Fuel Indicator, Above Normal .................... 141
8.6.2 Code No. SPN: 100, FMI: 3 - Engine Oil Pressure,Voltage Out of Range.............. 142
8.6.3 Code No. SPN: 100, FMI: 4 - Engine Oil Pressure, Volt. Out/Range...................... 142
8.6.4 Code No. SPN: 100, FMI:18 - Engine Oil Pressure, Below Normal ........................ 142
8.6.5 Code No. SPN: 105, FMI: 3 - Intake Manifold Temperature, Volt. Out/Range........ 142
8.6.6 Code No. SPN: 105, FMI: 4 - Intake Manifold Air Temperature Signal Out of
Range ....................................................................................................................... 142
8.6.7 Code No. SPN: 105, FMI: 15 - Intake Manifold Air Temperature High .................. 143
8.6.8 Code No. SPN: 105, FMI: 16 - Intake Manifold Temperature, Above Normal......... 143
8.6.9 Code No. SPN: 110, FMI: 3 - Engine Coolant Temperature, Volt. Out/Range........ 143
8.6.10 Code No. SPN: 110, FMI: 4 - Engine Coolant Temperature, Volt. Out/Range...... 143
8.6.11 Code No. SPN: 110, FMI: 15 - Engine Coolant Temperature, Above Normal ...... 143
8.6.12 Code No. SPN: 110, FMI: 16 - Engine Coolant Temperature, Above Normal ...... 144
8.6.13 Code No. SPN: 157, FMI: 10 - Fuel Rail Pressure Loss ....................................... 144
8.6.14 Code No. SPN: 157, FMI: 17 - Fuel Rail Pressure Not Developed ....................... 144
8.6.15 Code No. SPN: 158, FMI: 17 - Battery Potential, Below Normal........................... 145
8.6.16 Code No. SPN: 174, FMI: 3 - Fuel Temperature, Volt. Out/Range ....................... 145

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8.6.17 Code No. SPN: 174, FMI: 4 - Fuel Temperature, Volt. Out/Range ....................... 145
8.6.18 Code No. SPN: 174, FMI: 16 - Fuel Temperature, Above Normal ........................ 145
8.6.19 Code No. SPN: 189, FMI: 00 - Engine Speed Derate .......................................... 145
8.6.20 Code No. SPN: 620, FMI: 3 - 5 Volts DC Supply, Volt. Out/Range ...................... 146
8.6.21 Code No. SPN: 620, FMI: 4 - 5 Volts DC Supply, Volt. Out/Range ..................... 146
8.6.22 Code No. SPN: 636, FMI: 2 - Camshaft Position Signal Invalid ........................... 146
8.6.23 Code No. SPN: 636, FMI: 5 - Camshaft Position Circuit Resistance High ........... 146
8.6.24 Code No. SPN: 636, FMI: 6 - Camshaft Position Circuit Resistance Low ........... 147
8.6.25 Code No. SPN: 636, FMI: 8 - Camshaft Position Signal Missing ......................... 147
8.6.26 Code No. SPN: 636, FMI: 10 - Camshaft Position Signal Rate of Change
Abnormal .................................................................................................................. 148
8.6.27 Code No. SPN: 637, FMI: 2 - Timing (Crank) Sensor, Data Erratic ...................... 148
8.6.28 Code No. SPN: 637, FMI: 5 - Crankshaft Position Circuit Resistance High ......... 148
8.6.29 Code No. SPN: 637, FMI: 7 - Crankshaft and Camshaft Signals Out of Sync ..... 149
8.6.30 Code No. SPN: 637, FMI: 8 - No Crankshaft Position Signal ............................... 149
8.6.31 Code No. SPN: 637, FMI: 10 - Timing (Crank) Sensor, Abnormal Rt/Chg............ 150
8.6.32 Code No. SPN: 640, FMI: 31 - External Derate Commanded ............................... 150
8.6.33 Code No. SPN: 651, FMI: 2 - Injector #1 Part Number Invalid ............................. 150
8.6.34 Code No. SPN: 651, FMI: 5 - Injector #1 High Resistance ................................... 150
8.6.35 Code No. SPN: 651, FMI: 6 - Injector #1 Circuit Resistance Low ......................... 150
8.6.36 Code No. SPN: 651, FMI: 7 - Injector #1 Not Responding.................................... 151
8.6.37 Code No. SPN: 651, FMI: 13 - Calibration Fault: Injector #1 ............................... 151
8.6.38 Code No. SPN: 652, FMI: 2 - Injector #2 Part Number Invalid.............................. 151
8.6.39 Code No. SPN: 652, FMI: 5 - Injector #2 High Resistance ................................... 151
8.6.40 Code No. SPN: 652, FMI: 6 - Injector #2 Circuit Resistance Low ......................... 151
8.6.41 Code No. SPN: 652, FMI: 7 - Injector #2 Not Responding.................................... 152
8.6.42 Code No. SPN: 652, FMI: 13 - Calibration Fault: Injector #2 ............................... 152
8.6.43 Code No. SPN: 653, FMI: 2 - Injector #3 Part Number Invalid.............................. 152
8.6.44 Code No. SPN: 653, FMI: 5 - Injector #3 High Resistance ................................... 152
8.6.45 Code No. SPN: 653, FMI: 6 - Injector #3 Circuit Resistance Low ......................... 152
8.6.46 Code No. SPN: 653, FMI: 7 - Injector #3 Not Responding ................................... 153
8.6.47 Code No. SPN: 653, FMI: 13 - Calibration Fault: Injector #3 ................................ 153
8.6.48 Code No. SPN: 654, FMI: 2 - Injector #4 Part Number Invalid.............................. 153
8.6.49 Code No. SPN: 654, FMI: 5 - Injector #4 High Resistance ................................... 153
8.6.50 Code No. SPN: 654, FMI: 6 - Injector #4 Circuit Resistance Low ........................ 153
8.6.51 Code No. SPN: 654, FMI: 7 - Injector #4 Not Responding ................................... 154
8.6.52 Code No. SPN: 654, FMI: 13 - Calibration Fault: Injector #4 ............................... 154
8.6.53 Code No. SPN: 971, FMI: 31 - Engine Derate Switch ........................................... 154
8.6.54 Code No. SPN: 1076, FMI: 0 - Fuel Injection Pump Valve, Above Normal........... 154
8.6.55 Code No. SPN: 1076, FMI: 1 - Fuel Injection Pump Valve, Above Normal........... 154
8.6.56 Code No. SPN: 1076, FMI: 7 - Fuel Injection Pump Valve, Above Normal........... 155
8.6.57 Code No. SPN: 1347, FMI: 3 - Suction Control Valve Signal Out of Range High
................................................................................................................................... 155
8.6.58 Code No. SPN: 1347, FMI: 5 - Suction Control Valve Signal High Resistance
................................................................................................................................... 155
8.6.59 Code No. SPN: 1347, FMI: 7 - Fuel Rail Pressure Does Not Match
Commanded ............................................................................................................. 155

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8.6.60 Code No. SPN: 1349, FMI: 2 - Detected Fuel Rail Pressures Do Not Match ...... 156
8.6.61 Code No. SPN: 1349, FMI: 3 - Secondary Fuel Rail Pressure Signal Out of
Range High................................................................................................................ 156
8.6.62 Code No. SPN: 1349, FMI: 4 - Secondary Fuel Rail Pressure Signal Out of
Range Low ............................................................................................................... 156
8.6.63 Code No. SPN: 1136, FMI: 16 - ECU Temperature High ..................................... 156
8.6.64 Code No. SPN: 2000, FMI: 13 - Incorrect ECU .................................................... 157
8.6.65 Code No. SPN: 523792, FMI: 4 - EPGDS LTC Pump Signal Out of Range Low
................................................................................................................................... 157
8.6.66 Code No. SPN: 524099, FMI: 11 - EPGDS LTC Pump Blockage ........................ 157

9. SPECIFICATIONS ..................................................................................................................... 159

9.1 MDDCA, MDDCB, MDDCC, MDDCD, MDDCL, MDDCM, MDDCN, and MDDCP
Specifications Table ............................................................................................................ 159
9.2 MDDCE, MDDCF, MDDCG and MDDCR Specifications Table ......................................... 162
9.3 MDDCH, MDDCJ, and MDDCK Specifications Table ........................................................ 166

10. MAINTENANCE RECORD ....................................................................................................... 171

APPENDIX A. WIRING DIAGRAMS ............................................................................................... 173

A.1 Wiring Diagrams ................................................................................................................. 175

APPENDIX B. OUTLINE DRAWINGS ............................................................................................ 179

B.1 MDDCA, MDDCB, MDDCC, MDDCF, MDDCG, MDDCK, MDDCL, MDDCM and
MDDCN Outline Drawing .................................................................................................... 181
B.2 MDDCD, MDDCE, MDDCH, MDDCJ, MDDCP and MDDCR Outline Drawing ................. 185

APPENDIX C. WIRING HARNESSES............................................................................................ 189

C.1 MDD Wiring Harness.......................................................................................................... 191

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1 Safety Precautions
1.1 Overview
WARNING
The generator set is not a life support system
The generator set can stop without warning. Adults, children, persons with physical or mental
limitations, and pets could suffer personal injury or death.
A personal attendant, redundant power, or alarm system must be used if generator set operation
is critical.

NOTICE
This generator set is not to be the main source of power for communication and steering
systems. It can stop without warning.

Thoroughly read the Operator Manual before operating the generator set. It contains important instructions
that should be followed during operation and maintenance. Safe operation and top performance can only
be achieved when equipment is properly operated and maintained. The owners and operators of the
generator set are solely responsible for its safe operation.
Generator set operation, maintenance, and installation must comply with all applicable local, state, and
federal codes and regulations. Electricity, fuel, exhaust, moving parts, and batteries present hazards which
can result in severe personal injury or death. Only trained and experienced personnel with knowledge of
fuels, electricity, and machinery hazards shall perform generator set installation or adjustment procedures.
Also, only trained and experienced personnel with knowledge of fuels, electricity, and machinery hazards
shall remove, dismantle, or dispose of the generator set.
SAVE THESE INSTRUCTIONS.

1.2 Precaution Symbols

The following symbols used in this manual alert you to potential hazards to operator, maintenance
personnel, and equipment.

DANGER
Indicates a hazardous situation that, if not avoided, will result in death or serious injury.

WARNING
Indicates a hazardous situation that, if not avoided, could result in death or serious injury.

CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.

NOTICE
Indicates information considered important, but not hazard-related (e.g., messages relating to
property damage).

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1. Safety Precautions 6-2018

1.3 General Safety Precautions

WARNING
Hot, moving, and electrically live parts
Hot, moving, and electrically live parts can cause severe personal injury or death.
Keep children away from the generator set.

WARNING
Hot,Moving and Electrically live parts
Hot,Moving and Electrically live parts can cause severe personal injury or death.
Only trained and experienced personnel should make adjustments while the generator set is
running.

WARNING
Electrical Generating Equipment
Incorrect operation can cause severe personal injury or death.
Do not operate equipment when fatigued, or after consuming any alcohol or drug.

WARNING
Electrical Generating Equipment
Incorrect operation and maintenance can result in severe personal injury or death.
Make sure that only suitably trained and experienced service personnel perform electrical and/or
mechanical service.

WARNING
Moving Parts
Moving parts can cause severe personal injury.
Use extreme caution around moving parts. All guards must be properly fastened to prevent
unintended contact.

WARNING
Moving Parts
Running the generator set without the cover or service door can cause severe personal injury or
equipment damage.
Do not operate the generator set with the cover or service doors removed.

WARNING
Hot Pressurized Liquid
Contact with hot liquid can cause severe burns.
Do not open the pressure cap while the engine is running. Let the engine cool down before
removing the cap. Turn the cap slowly and do not open it fully until the pressure has been
relieved.

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WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns.
The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear
appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING
Combustible Liquid
Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death.
Do not store fuel, cleaners, oil, etc., near the generator set.

WARNING
Combustible Liquid
Ignition of combustible liquids is a fire or explosion hazard which can cause severe burns or
death.
Do not use combustible liquids like ether.

WARNING
Toxic Hazard
Ethylene glycol, used as an engine coolant, is toxic to humans and animals.
Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance with
local environmental regulations.

WARNING
Toxic Hazard
Used engine oils have been identified by some state and federal agencies to cause cancer or
reproductive toxicity.
Do not ingest, breathe the fumes, or contact used oil when checking or changing engine oil.
Wear protective gloves and face guard.

WARNING
Carbon Monoxide
Inhalation of carbon monoxide can cause severe personal injury or death.
Test and confirm that all carbon monoxide detectors are working in accordance with the
manufacturer's instructions or owner's manual prior to every startup, and after 8 hours of
running.

WARNING
Toxic Gases
Substances in exhaust gases have been identified by some state and federal agencies to cause
cancer or reproductive toxicity.
Do not breathe in or come into contact with exhaust gases.

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1. Safety Precautions 6-2018

WARNING
Fire Hazard
Accumulated grease and oil are a fire hazard. Fire can cause severe burns or death.
Keep the generator set and the surrounding area clean and free from obstructions. Repair oil
leaks promptly.

WARNING
Accidental or remote starting
Accidental starting of the generator set while working on it can cause severe personal injury or
death
To prevent accidental or remote starting while working on the generator set, disconnect the
negative (–) battery cable at the battery using an insulated wrench.

NOTICE
Unsecured or loose fasteners can cause equipment damage. Make sure all fasteners are secure
and properly torqued.

NOTICE
Keep multi-type ABC fire extinguishers close by. Class A fires involve ordinary combustible
materials such as wood and cloth. Class B fires involve combustible and flammable liquid fuels
and gaseous fuels. Class C fires involve live electrical equipment. (Refer to NFPA No. 10 in the
applicable region.)

1.4 Electrical Shocks and Arc Flashes Can Cause

Severe Personal Injury or Death
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause severe burns or death.
Contact with exposed energized circuits with potentials of 50 Volts AC or 75 Volts DC or higher
can cause electrical shock and electrical arc flash. Refer to standard NFPA 70E or equivalent
safety standards in corresponding regions for details of the dangers involved and for the safety
requirements.

Guidelines to follow when working on de-energized electrical systems:

• Use proper PPE. Do not wear Jewellery and make sure that any conductive items are removed from
pockets as these items can fall into equipment and the resulting short circuit can cause shock or
burning. Refer to standard NFPA 70E for PPE standards.
• De-energize and lockout/tagout electrical systems prior to working on them. Lockout/Tagout is
intended to prevent injury due to unexpected start-up of equipment or the release of stored energy.
Please refer to the lockout/tagout section for more information.
• De-energize and lockout/tagout all circuits and devices before removing any protective shields or
making any measurements on electrical equipment.
• Follow all applicable regional electrical and safety codes.

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6-2018 1. Safety Precautions

Guidelines to follow when working on energized electrical systems:

NOTICE
It is the policy of Cummins Inc. to perform all electrical work in a de-energized state. However,
employees or suppliers may be permitted to occasionally perform work on energized electrical
equipment only when qualified and authorized to do so and when troubleshooting, or if de-
energizing the equipment would create a greater risk or make the task impossible and all other
alternatives have been exhausted.

NOTICE
Exposed energized electrical work is only allowed as per the relevant procedures and must be
undertaken by a Cummins authorized person with any appropriate energized work permit for the
work to be performed while using proper PPE, tools and equipment.

In summary:
• Do not tamper with or bypass interlocks unless you are authorized to do so.
• Understand and assess the risks - use proper PPE. Do not wear Jewellery and make sure that any
conductive items are removed from pockets as these items can fall into equipment and the resulting
short circuit can cause shock or burning. Refer to standard NFPA 70E for PPE standards.
• Make sure that an accompanying person who can undertake a rescue is nearby.

1.5 Generator Set Voltage Is Deadly

• Generator set electrical output connections must be made by a trained and experienced electrician
in accordance with applicable codes.
• Use caution when working on live electrical equipment. Remove all jewelry, make sure clothing and
shoes are dry, stand on a dry wooden platform or rubber insulating mat, and use tools with insulated
handles.

1.6 Engine Exhaust Is Deadly

• Properly working carbon monoxide detectors must be located in all living areas of the boat.
• Never occupy the boat while the generator set is running unless the boat is equipped with properly
working marine carbon monoxide detectors.
• The exhaust system must be installed in accordance with the generator set Installation Manual and
be free of leaks.
• Prior to every startup and after every eight hours of running, all carbon monoxide detectors must be
tested and confirmed to be working in accordance with the manufacturer instructions or owner
manual.
• Make sure the bilge is adequately ventilated with a power exhauster or blower.
• Inspect for exhaust leaks at every startup and after every eight hours of operation.
• For more information about carbon monoxide see American Boat and Yacht Council (ABYC)
publication TH-22—Educational Information About Carbon Monoxide.

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1.7 Diesel Fuel Is Combustible

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

1.8 Battery Gas Is Explosive

• Wear splash-proof safety glasses.
• Do not smoke or permit flames or sparks to occur near the battery at any time or anywhere near the
generator set.
• To reduce arcing when disconnecting or reconnecting battery cables, always disconnect the
negative (–) battery cable first and reconnect it last.

1.9 Moving Parts Can Cause Severe Personal Injury or

Death
• Do not wear loose clothing or jewelry near moving parts such as PTO (power take-off) shafts, fans,
belts, and pulleys.
• Keep hands away from moving parts.
• Keep protective guards in place over fans, belts, pulleys, and other moving parts.

1.10 Flammable Vapor Can Cause a Diesel Engine to

Overspeed
WARNING
Flammable Vapour
Flammable Vapour can cause an engine to overspeed and become difficult to stop, resulting in
possible fire, explosion, severe personal injury, and death.
Do not operate a generator set where a flammable vapor environment can be created, unless the
generator set is equipped with an automatic safety device to block the air intake and stop the
engine.

The owners and operators of the generator set are solely responsible for operating the generator set
safely. Contact your authorized Cummins distributor for more information.

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1.11 Hazards of Carbon Monoxide

WARNING
Toxic Hazard
Engine-driven Generator Sets can produce harmful levels of carbon monoxide causing nausea,
fainting, or death.
Make sure the generator set is well maintained and the boat is well ventilated. Recommended
carbon monoxide detectors and alarms are installed.

1.11.1 Carbon Monoxide Poisoning

Carbon Monoxide (CO) is an odorless, colorless, tasteless, and non-irritating gas. You cannot see it or
smell it. Exposure, even to low levels of CO, for a prolonged period can lead to asphyxiation (lack of
oxygen) resulting in death.
Mild effects of CO poisoning include:
• eye irritation
• dizziness
• sleepiness
• headaches
• fatigue
• inability to think clearly
More extreme symptoms include:
• vomiting
• seizures
• collapse

1.11.2 Special Risks of CO on Boats

Depending on air temperature and wind, CO can accumulate between hulls, under an overhanging deck
or rear swimming platform, and in and around the boat. A swimmer can be exposed to lethal levels of CO
when the generator set is running. Passengers on deck and in the living quarters can also be exposed,
especially when the boat is docked, beached, or tied to a neighboring boat.
The risk of exposure to CO can be multiplied greatly by the "station wagon" effect, obstructions that block
exhaust dissipation, and infiltration from neighboring boats. To protect against all three situations, it is
recommended that reliable and approved marine CO detector alarms be installed on your boat.
• The Station Wagon Effect: A boat pushes aside the air through which it is moving, causing a zone
of low pressure in the back of the boat and cabins into which exhaust gases can be drawn (see
figure below). A breeze across an anchored boat can have the same effect. Opening doors and
windows so that air can flow through the boat can reduce the effect.

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1. Safety Precautions 6-2018

FIGURE 1. STATION WAGON EFFECT

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

1.11.3 Protection from CO Poisoning

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

1.12 Substances Hazardous to Health

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

1.12.1 Antifreeze (Fleetguard - ES Compleat and EG Premix)

This antifreeze is also known as an ethylene glycol based coolant, summer coolant, coolant additive. It is
a purple-colored viscous liquid with a mild chemical odor, is soluble in water, and is harmful under certain
conditions. It contains ethylene glycol and diethylene glycol. Ethylene glycol is a potentially hazardous
constituent.
The substance has a boiling point of 107° C (224.6° F) and a flash point of 121° C (249.8° F).
It is used as an engine coolant additive and can be found in engine cooling systems and heat exchangers.
Installers, operators, and maintainers are likely to encounter this substance.

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[Link] Hazardous Reactions

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

[Link] Protective Measures

Refrain from eating, drinking, or smoking when using the product. Adopt a high standard of personal
hygiene. In case of skin contact, wash immediately with soap and water.
Ensure good ventilation and avoid heat sources. Avoid breathing mist. If there is a risk of vapor or
particulate, use a suitable organic vapor mask.
Eye protection, gloves, overalls, and an impervious apron should be worn. Avoid contamination inside the
gloves. If overalls become contaminated, discontinue use and clean thoroughly.

[Link] Storage and Transport

Store and transport only in correctly marked containers. Keep containers closed when not in use. Keep
cool, out of sunlight, and away from naked flames and strong acids. Do not freeze. Store well away from
food-stuffs and drinking water. Take special care to avoid discharge into drains, sewers, and water-course.
Contain leaks and spills with sand, earth, or non-combustible absorbent material to prevent entry of
substance into drains (sewage systems), water-courses, and land. Eliminate all ignition sources. Use a
plastic shovel to transfer to a suitable container. Dispose of unwanted or absorbed substance through an
authorized contractor to a licensed site.

[Link] Emergency Action

Emergency Type Action
Fire Fire fighters are to use self-contained breathing apparatus. Keep fire-exposed containers
cool. Prevent run-off from entering waterways, drains, and drinking water supplies.
Extinguishing media: CO2, alcohol resistant foam, dry powder, or water spray.
Ingestion Toxic by ingestion. If swallowed, contact a doctor or poison control center. Induce vomiting
only under the advice of a doctor or poison control center. Delayed treatment may result in
fatality.
Inhalation Remove from further exposure. In case of irritation to lungs or throat, seek medical advice.
(of Vapor)
Aspiration (Inhalation Obtain immediate medical assistance.
of Liquid)
Eyes Flush copiously with water or preferably eye-wash solution for at least five minutes. Seek
medical advice.
Skin Wash thoroughly with soap and water and seek medical attention if irritation develops.
Change clothing if necessary and wash clothing before re-use.

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Emergency Type Action

Spillage Soak up using an absorbent material and dispose of as directed under Storage and
Transport.

1.12.2 Gas Oil

This product is also known as red diesel, fuel oil, and type A1 or A2. It can be pale red or clear liquid with
a characteristic mild odor. It contains catalytically cracked oil, petroleum distillates, quinizarin, and gas oil
maker dye red. The catalytically cracked oil and petroleum distillates are potentially hazardous
constituents.
The substance has an initial boiling point of 180 °C (345 °F), a flash point greater than 56 °C (132.8 °F), a
vapor pressure less than 0.7 mm Hg at 20 °C (68 °F), and has negligible solubility in water.
It is used as a fuel for off-road diesel powered vehicles and stationary engines and can be found in fuel
tanks, pipes, and injection systems. The substance should not be used for any other purpose without
contacting the manufacturer or supplier. Installers, operators, and maintainers are likely to encounter this
substance.

[Link] Hazardous Reactions

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

[Link] Protective Measures

Ensure good ventilation and avoid heat sources. Observance of good housekeeping rules ensures general
safety. Do not smoke. Avoid breathing mist.
When working on or testing injection equipment, special care is required to avoid perforation of skin by
high pressure fuel. Use eye protection in the event of suspected high pressure leak.
Adopt a high standard of personal hygiene. In the case of skin contact, wash well with soap and water.
Use gloves, overalls, and eye protection if there is a risk of splashing. Use oil-impervious gloves and avoid
contamination inside the gloves. If overalls become contaminated, discontinue use and clean thoroughly.
Contaminated clothing should be removed, soaked with water, and laundered before re-use.
No special respiratory precautions are necessary in normal use.
Do not use as a solvent for removing dirt and grease, etc., from skin.

[Link] Storage and Transport

Store and transport only in correctly marked containers. Keep containers closed when not in use. Keep
cool, out of sunlight, and away from naked flames. Electrical continuity is required between the transport
and storage vessels during product transfer.
Contain leak or spill with sand, earth, or other suitable material, and prevent entry of substance into
drainage (sewage system), water-courses, and land. Dispose of unwanted or absorbed substance through
an authorized contractor to a licensed site.

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Inform fire and local authorities should the product reach waterways, drains, etc.

[Link] Emergency Action

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

1.12.3 Lubricant Oil - Premium Blue E 15W40

Also known as oil, lube oil, sump oil. New oil is a dark, viscous liquid with a slight characteristic odor. The
base oil contains distillates (petroleum) and solvent-dewaxed heavy paraffinic. It is not classified as
dangerous according to Directive 1999/45/EC and its amendments, and is not classified according to the
EU regulations.
It has a boiling point greater than 150° C (302° F), and a flash point Open Cup of 220° C (438° F)
(Cleveland) and is insoluble in cold water.
It is used in engine lubricant oil systems, sump pan and filters, make-up tanks, and piping systems as a
lubrication oil for use in a wide range of diesel engines operating under severe conditions. Installers,
operators, and maintainers are likely to encounter this product.

[Link] Hazardous Reactions

This product is stable, although slightly re-active, with oxidizing agents. Results of decomposition are
carbon oxides (CO, CO2) and water.
Although harmful if ingested (swallowed) or aspirated (breathed in), repeated or prolonged exposure is not
known to aggravate medical conditions.
Used oil may contain harmful combustion by-products and un-burnt fuel that can cause skin reactions as
detailed for fuel. Particular care must be taken if oil from a severely overheated engine is handled. Use
impervious gloves, lab coat, and safety glasses. Do not breathe vapor or spray.

[Link] Protective Measures

Ensure good ventilation and avoid heat sources.
Adopt a high standard of personal hygiene. In case of skin contact, wash thoroughly with soap and water.
Use safety glasses, impervious gloves, and lab coat. Avoid contamination inside the gloves. If overalls
become contaminated, discontinue use and clean thoroughly.

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No special respiratory precautions are necessary in normal use. Do not breathe vapor or spray when
handling hot materials.

[Link] Storage and Transport

Store and transport only in correctly marked containers. Keep containers tightly sealed when not in use.
Keep in cool, well ventilated area, out of sunlight and away from naked flames. Store well away from food-
stuffs and drinking water.
Wear splash goggles, full suit, boots, and gloves. Absorb leaks or spills with an inert material and dispose
of unwanted or absorbed substance through an authorized contractor to a licensed site. Finish cleaning by
spreading water on the contaminated surface and allow to evacuate through the sanitary system.

[Link] Emergency Action

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

1.13 Generator Set Warning Labels

Warning signs are provided on the generator set at or near the point of risk. To avoid injury, always take
the necessary precautions as indicated on the sample signs shown below.

Caution or Warning.
Indicates a risk of personal injury.

Caution or Warning of Temperature Hazard.

Indicates a risk of personal injury from high temperature.

Caution or Warning of High Voltage Hazard.

Indicates a risk of personal injury from electric shock or electrocution.

Caution or Warning of Engine Coolant Pressure Hazard.

Indicates a risk of personal injury from hot pressurized engine coolant.

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Caution or Warning.
Indicates to read Operator Manual for additional information.

Caution or Warning of No Step.

Indicates a risk of personal injury or equipment damage from stepping on equipment.

Caution or Warning of Combustion or Explosion Hazard.

Indicates a risk of personal injury from explosion.

Caution or Warning of Belt and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.

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

Indicates a risk of personal injury or asphyxiation from poisonous fumes or toxic gases.

Caution or Warning of High Voltage or Current Source Hazard.

Indicates a risk of personal injury from electrical shock or electrocution.

Caution or Warning of Fan and Rotating Part Hazard.

Indicates a risk of personal injury from entanglement in moving parts.

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Copyright © 2018 Cummins Inc. 14 0981-0539 (Issue 9)

2 Introduction
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or death.
Make sure that only a trained and experienced electrician makes generator set electrical output
connections, in accordance with the installation instructions and all applicable codes.

WARNING
Electrical Generating Equipment
Faulty electrical generating equipment can cause severe personal injury or death.
Generator sets must be installed, certified, and operated by trained and experienced person in
accordance with the installation instructions and all applicable codes.

2.1 About This Manual

This is the service manual for the generator set or sets listed on the front cover.
The information contained within the manual is based on information available at the time of going to print.
In line with Cummins Inc. policy of continuous development and improvement, information may change at
any time without notice. Therefore, the users should make sure that before starting any work, they have
the latest information available. The latest version of this manual is available on QuickServe Online
([Link]
This manual includes generator set specifications, troubleshooting resolutions for all fault codes,
maintenance schedule, service and maintenance procedures for the generator set control, engine,
accessories, and alternator, as well as instructions for adjusting the AC output voltage and changing the
generator set frequency.
See the related parts manual for part identification numbers and required quantities. Genuine Cummins
replacement parts are recommended for best results.

2.1.1 Warning - Generator Set Not Ignition Protected

NOTICE
The generator set or sets included in this manual are not ignition protected and shall not be used
in a flammable vapor environment.

NOTICE
Within the parts manual, MC parts are marine critical and must comply with boating safety
ignition protection, backfire, fire resistance, exhaust system integrity, or other requirements
established by regulatory agencies, such as the U.S. Coast Guard, ABYC, and ISO. When marine
critical parts are replaced for any reason, use Cummins parts that are identified with the part
numbers in the appropriate parts manual.

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2.2 Related Literature

Before any attempt is made to operate the generator set, the operator should take time to read all of the
manuals supplied with the generator set, and to familiarize themselves with the warnings and operating
procedures.

CAUTION
A generator set must be operated and maintained properly if you are to expect safe and reliable
operation. The Operator manual includes a maintenance schedule and a troubleshooting guide.
The Health and Safety manual must be read in conjunction with this manual for the safe
operation of the generator set:

• Health and Safety Manual (0908-0110-00)

The relevant manuals appropriate to your generator set are also available, the documents below are in
English:
• Operator Manual (0981-0172)
• Installation Manual (0981-0639)
• Service Manual (0981-0539)
• Parts Manual (0981-0276)
• Standard Repair Times - ES Family (0900-0633)
• Warranty Administration Manual (4021290)
• Global Commercial Warranty Statement (A028U870)

2.3 Model Identification

WARNING
Improper service or replacement of parts
Improper service or replacement of parts could lead to severe personal injury or death and
damage to equipment and property.
Service personnel must be qualified to perform electrical and mechanical service.

The generator set model name is found on the nameplate, which is mounted on the service side of the
generator set. See figure below. Every character is significant (the last character of the model number is
the specification letter, which is important for obtaining the right parts).

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2.3.1 Nameplate Location

FIGURE 2. NAMEPLATE LOCATION

2.4 Emissions Label

The emissions label states compliance with applicable engine emissions regulations for US EPA certified
models (17 MDKDP, 21.5 MDKDR, and 29 MDKDS). Refer also to the Federal Emissions Design And
Defect Limited Warranty For C.I. Engine (Diesels) publication that was shipped in the same package as
the Operator Manual.

NOTICE
The emissions warranty statement is for EPA certified only products.

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2.4.1 Emission Label Location

No. Description No. Description

1 Engine Option Codes Label 3 Engine Serial Number Plate
2 Engine Emissions Label

FIGURE 3. TYPICAL ENGINE LABEL LOCATIONS

2.5 Noise
Generator sets emit noise. As noise level and time of exposure increase, risk of hearing damage
increases. The Model Specifications section includes specific noise level information for these generator
sets. Use personal hearing protection appropriate for your exposure to generator set noise.
When used in countries where compliance to the EU Noise directive is required: This generator set has
not been evaluated and is not marked for use in open air. Install the generator set in accordance with the
Installation Manual. Obey local noise restrictions when you operate the generator set.

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2.6 Electromagnetic Compatibility Compliance

Generator sets emit and receive electromagnetic (radio frequency) energy. If the generator set affects
operation of nearby devices, or nearby devices affect generator set operation, increase the distance
between them.
When used in countries where compliance to the EMC directive is required: This generator set has been
evaluated for use in the residential, commercial, and light industrial environments.

2.7 Build Standards

The generator set and its control system have been designed, constructed and tested generally in
accordance with the following Standards where applicable.

Standard Title
BS EN 1037:1995+a1:2008 Safety of machinery - Prevention of unexpected start up.
BS EN ISO 14121-1:2007 Safety of machinery. Risk assessment principles.
BS EN ISO 13857:2008 Safety of machinery. Safety distances to prevent hazard zones being
reached by upper and lower limbs.
BS EN 349:1993+A1:2008 Safety of machinery - Minimum gaps to avoid crushing parts on the human
body.
BS EN 547-1:1996+A1:2008 Safety of machinery - Human body dimensions - Part 1: Principles for
determining the dimensions required for openings for whole body access
into machinery.
BS EN 547-2:1996+A1:2008 Safety of machinery - Human body dimensions - Part 2: Principles for
determining the dimensions required for access openings.
BS EN 547-3:1996+A1:2008 Safety of machinery - Human body dimensions - Part 3: Anthropomorphic
data.
BS EN 60204-1:2006+A1:2009 Safety of machinery. Electrical equipment of machines. General
requirements.
BS EN 614-1:2006+A1:2009 Safety of machinery. Ergonomic design principles. Terminology and
general principles.
BS EN 953:1997+A1:2009 Safety of machinery - Guards - General requirements for the design and
construction of fixed and movable guards.
BS EN ISO 12100-1:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design. Basic
terminology, methodology
BS EN ISO 12100-2:2003+A1:2009 Safety of machinery. Basic concepts, general principles for design.
Technical principles
BS EN ISO 13732-1:2008 Ergonomics of the thermal environment. Methods for the assessment of
human responses to contact with surfaces. Hot surfaces
BS EN ISO 13849-1:2008 Safety of machinery - Safety-related parts of control systems
BS EN ISO 13850:2006 Safety of machinery - Emergency stop. Principles for design.
BS EN 61310-1:2008 Safety of machinery - Indication, marking and actuation - Part 1:
Requirements for visual, auditory and tactile signals.

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Standard Title
BS EN 61310-2:2008 Safety of machinery - Indication, marking and actuation - Part 2:
Requirements for marking.
BS EN 61000-6-1:2007 Electromagnetic compatibility (EMC). Generic standards. Immunity
standard for residential, commercial and light-industrial environments.
BS EN 61000-6-3:2007 Electromagnetic compatibility (EMC). Generic standards. Emission
standard for residential, commercial and light-industrial environments.
BS EN 1299:1997+A1:2008 Mechanical vibration and shock - Vibration isolation of machines -
Information for the application of source isolation
BS EN 1679-1:1998 Reciprocating internal combustion engines - Safety - Part 1: Compression
ignition engines
BS EN 12601:2001 Reciprocating internal combustion engine driven generating sets - Safety

Copyright © 2018 Cummins Inc. 20 0981-0539 (Issue 9)

3 Maintenance
3.1 Periodic Maintenance
Periodic maintenance is essential for top performance and long generator set life. Use the Periodic
Maintenance Schedule below as a guide for normal periodic maintenance.
Maintenance, replacement, or repair of emission control devices and systems may be performed by any
engine repair establishment or individual. However, warranty work must be completed by an authorized
Cummins Inc. service representative.
To help keep generator set maintenance regular and provide a basis for warranty claims, record
maintenance performed, see Chapter 10 on page 171.

3.1.1 Periodic Maintenance Schedule

TABLE 1. PERIODIC MAINTENANCE SCHEDULE

Every Every Every

MAINTENANCE OPERATION Every Every Initial
500 hrs / 2000 hrs 6000 hrs
Day/8 Monthly 250 hrs / Break-in
12 / 24 / 72
Hrs 6 months / 100 hrs
months months months
General Inspection1 x
Check Engine Oil Level x
Check Engine Coolant Level x
Inspect and Clean Sea Water Strainer x
Check Sea Water Pump for Leaks x
Inspect Accessory Belt3 x
Squeeze Dust Unloader on Air Filter x
Drain Water From Fuel Filters x
Check Battery and Battery Connections2 x
Check Siphon Break x
Change Oil and Filter x x
Inspect Engine Mounts x
3
Inspect Serpentine Belt Tensioner x
Replace CCV Filter4 x
Change Fuel Filters x
Inspect Air Intake Lines x
Inspect/Replace Air Filter5 x
Inspect Zinc Anode x

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Replace Raw Water Pump Impeller x

Adjust Valve Lash6 x
Test Coolant and Pressure Cap x
Replace Fuel Injectors x
Inspect Generator Bearings x
Inspect and Clean Heat Exchanger x
Check Rubber Crankshaft Vibration
x
Damper
Replace and Flush Coolant x
Test Thermostats x
1 - Includes inspection of oil level, coolant level, fuel system, exhaust system, batteries and battery connections.
2 - See battery manufacturer's recommendations.
3 - Check for slippage, cracking, wear, and tension.
4 - Shut down engine for 2 minutes every 24 hours to allow for drainage of crankcase oil.
5 - Clean and oil if restriction is greater than 52 inches (625 mm) WC. The air cleaner housing has a 1/4 inch NPT
tap.
6 - Must be performed by a qualified mechanic (authorized Cummins Dealer).

3.2 General Inspection

Inspect the following before the first start of the day and after every eight hours of operation.
• Battery Connections
• Oil Level
• Fuel System
• Coolant Level
• Raw Water System
• Exhaust System
• Mechanical System
Review the following figure for assistance in locating various service points.

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3.2.1 Service Point Locations

No. Description No. Description

1 Line Circuit Breaker 9 CCV Filter
2 Control Panel 10 Oil Drain Hose Exit
3 Air Filter Housing 11 Oil Drain Valve
4 Secondary Fuel Filter 12 Oil Filter
5 Fuel Lift Pump with Priming Lever 13 Oil Dipstick
6 Primary Fuel Filter 14 Raw Water Pump
7 Oil Fill Cap 15 Serpentine Belt Guard (Unhoused Gensets)
8 Fuel Return and Supply Fittings (1/4 inch NPTF)

FIGURE 4. TYPICAL SERVICE SIDE SERVICE POINTS

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No. Description No. Description

1 Zinc Anode in Heat Exchanger End Cap (Both Ends) 6 Coolant Drain Cocks
2 Coolant Thermostat Housing 7 Battery (+) Connection - M12 Stud (Non-Isolated
Ground) - M10 Stud (Isolated Ground)
3 Coolant Pressure Cap and Fill Neck 8 Battery (-) Connection for Isolated-Ground M10 Stud
4 Coolant Fill Vent Cock (On Top of Head Next to 9 Battery (-) Connection for Non-Isolated Ground &
Lifting Eye) GenSet Ground (Vessel Bond) M12 Screw
5 Raw Water Hose Between Rear End Cap of Heat
Exchanger and Water-Exhaust Mixer Elbow
(Installation May Require Siphon Break - See
Installation Manual)

FIGURE 5. TYPICAL NON-SERVICE SIDE SERVICE POINTS

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3.2.2 Battery Connections

WARNING
Fire Hazard
Flames, sparks, or arcing at battery terminals, light switches, or other equipment can ignite
battery gas, causing severe personal injury.
Ventilate the battery area before working on or near a battery, wear safety glasses, and do not
smoke. Turn work light on or off away from the battery.

NOTICE
When performing maintenance procedures or when servicing a battery, stop the generator set
and disconnect the charger before disconnecting battery cables. Using an insulated wrench,
disconnect the negative (–) cable first and reconnect it last.

Check the battery terminals for clean, tight connections. Loose or corroded connections have high
electrical resistance which makes starting harder.

3.2.3 Oil Level

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns.
The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear
appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING
Crankcase Pressure
Crankcase pressure can blow hot engine oil out the fill opening causing, severe burns.
Always stop the generator set before removing the oil fill cap.

WARNING
Toxic Hazard
State and federal agencies have determined that contact with used engine oil can cause cancer
or reproductive toxicity.
Avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin.

NOTICE
Too little oil can cause severe engine damage. Too much oil can cause high oil consumption.
Keep the oil level between the high and low beads (or markings) on the dipstick.

1. Shut off the generator set.

2. Pull the oil fill plug and dipstick out of the oil fill neck. The plug may be difficult to pull straight out - tilt
the plug in its socket while pulling out.
3. Wipe off the dipstick and thread it back into the fill neck. Seat the plug, which snaps into its socket.

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4. Remove the plug and dipstick again and check the oil level on the dipstick. Replace and seat the oil
fill plug.
5. Add or drain oil as necessary if the oil level is not within the bead markings (FULL or ADD markings).
See Section 3.4 on page 28 for oil recommendations.

NOTICE
It is not necessary to add oil between oil changes unless the oil level has dropped more
than 1/3 of the way between the high and low beads. A full quart (0.9 liter) can be added if
the oil level is at the lower bead.

FIGURE 6. OIL LEVEL DIPSTICK ADD/FULL MARKINGS

3.2.4 Fuel System Leaks

WARNING
Combustible Liquid
Fuel leaks are a fire or explosion hazard which can cause severe burns or death.
Do not run the generator set if there is an indication of a fuel leak or causes fuel to leak.

1. Check for leaks at hose, tube, and pipe fittings in the fuel supply and return systems while the
generator set is running and while it is stopped.
2. Check flexible fuel hoses for cuts, cracks, abrasions, and loose hose clamps.
3. Make sure fuel lines do not rub against other parts.
4. Replace worn or damaged fuel line parts before leaks occur. Replace hose with a high pressure fuel
injection system USCG TYPE A1 or ISO 7840-A1 fuel hose.
5. Prime the fuel system if the generator set ran out of fuel.

3.2.5 Coolant Level

The recovery tank is designed to maintain coolant level, not to fill the system. Keep the level of coolant in
the recovery tank between COLD and HOT. See Section 3.6.5 on page 41 for coolant specifications.
Also see Section 3.6.7 on page 42 for detailed instructions on refilling the cooling system.
1. Check coolant level in the recovery tank and, if necessary, refill the recovery tank to COLD when the
engine is cold or to HOT when it is at normal running temperature. Use the recommended antifreeze
mixture.

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2. If the tank is empty, check for and repair any coolant leaks and refill the system through the fill neck
on the engine. Use the recommended antifreeze mixture.

3.2.6 Raw Water System

1. Clean out the sea water strainer, if necessary.
2. Make sure the sea-cock is open for generator set operation.
3. When a water/exhaust separator is provided, open the sea-cock for the water drain hose.
4. Check for hoses that leak or are damaged. Have a qualified service person replace any leaking or
damaged hoses.

3.2.7 Exhaust System

WARNING
Toxic Gases
Inhalation of exhaust gases can cause severe personal injury or death.
Do not operate the generator set untill all exhaust leaks have been repaired.

1. Check that all CO monitors are working properly.

2. Inspect the exhaust system for leaks and loose hose clamps on:
• exhaust manifold
• exhaust elbow
• muffler
• water separator
• hull fittings
3. Replace any damaged sections of exhaust hose.

3.2.8 Mechanical System

1. Monitor generator set status using the digital display.
2. Visually check the generator set for mechanical damage.
3. For generator sets with sound shield, install service doors before running the generator set, then
listen for unusual noises when the generator set is running.
4. Check the generator set mounting bolts.
5. Check to see that the generator set air inlet and outlet openings are not clogged with debris or
blocked.
6. Keep the generator set compartment clean.

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3.3 Maintaining the Battery

WARNING
Fire Hazard
Flames, sparks, or arcing at battery terminals, light switches, or other equipment can ignite
battery gas, causing severe personal injury.
Ventilate the battery area before working on or near a battery, wear safety glasses, and do not
smoke. Turn work light on or off away from the battery.

Refer to Section 3.1 on page 21 for the battery maintenance schedule and follow the battery
manufacturer's instructions. Have the battery charging system serviced if DC system voltage is
consistently low or high.
Check the battery terminals for clean, tight connections. Loose or corroded connections have high
electrical resistance which makes starting harder.
1. Keep the battery case and terminals clean and dry.
2. Keep the battery terminals tight.
3. Remove battery cables with a battery terminal puller.
4. Make sure which terminal is positive (+) and which is negative (–) before making battery
connections, always removing the negative (–) cable first and reconnecting it last to reduce arcing.

3.4 Maintaining the Lubrication System

Keep dirt, water, and other contaminants from entering the lubrication system and corroding or clogging
lubrication components.

3.4.1 Oil Recommendations

Use API (American Petroleum Institute) classified engine oils according to the following guidelines.
• In emissions regulated areas it is mandatory to use CF, CF-4, CG-4, CH-4, or CI-4 class oil with:
◦ Low sulfur fuel - sulfur content less than 500 ppm (0.05% weight)
◦ Ultra low sulfur fuel - sulfur content less than 15 ppm (0.0015% weight).
• In non-emissions regulated areas use high sulfur fuel.
◦ If sulfur content is between 500 ppm (0.05% weight) and 5000 ppm (0.5% weight), CF class oil
is recommended. If CF-4, CG-4, CH-4, or CI-4 class oil is used, the oil and oil filter must be
changed twice as often as specified in Section 3.1 on page 21.
◦ If sulfur content is between 5000 ppm (0.5% weight) and 10,000 ppm (1.0% weight), use CF-4,
CG-4, CH-4, or CI-4 class oil. The oil and oil filter must be changed twice as often as specified
in Section 3.1 on page 21.
Look for the SAE (Society of Automotive Engineers) viscosity grade. Choose the viscosity grade
appropriate for the ambient temperatures expected until the next scheduled oil change. See figure below.
Multi-grade oils such as SAE 15W-40 are recommended for year round use.

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[Link] Oil Viscosity vs. Ambient Temperature

FIGURE 7. OIL VISCOSITY VS. AMBIENT TEMPERATURE

3.4.2 Changing Engine Oil and Filter

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING
Toxic Hazard
State and federal agencies have determined that contact with used engine oil can cause cancer
or reproductive toxicity.
Avoid skin contact and breathing of vapors. Use rubber gloves and wash exposed skin.

WARNING
Crankcase Pressure
Crankcase pressure can blow hot engine oil out the fill opening causing, severe burns.
Always stop the generator set before removing the oil fill cap.

Refer to Chapter 3 on page 21 for the engine oil change schedule.

1. Run the generator set under load until it is up to operating temperature, stop it, and disconnect the
negative (–) battery cable at the battery.
2. For generator sets with sound shield, remove service door.
3. Remove oil fill plug and open the drain valve. The drain valve has a 3/8 NPT outlet for connecting a
hose fitting to facilitate oil drainage.

NOTICE
If an oil pump-out system is installed, follow the instructions provided with the pump.

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NOTICE
Dispose of oil in accordance with local requirements.

4. Drain used oil into a suitable container.

5. Close the oil drain valve.
6. Remove the old oil filter or filters using a suitable filter wrench (available from Cummins) and
appropriately discard the filter or filters.
7. Remove the old gasket if it does not come off with the filter. Wipe the sealing surface clean.
8. Apply a film of oil to the new filter gasket and partly fill the new filter with oil so that it reaches engine
parts sooner at startup.
9. Spin the filter on by hand until the gasket just touches the mounting pad and tighten 3/4 of a turn.
10. Refill the engine with the proper type and amount of engine oil. See the previous section for oil
recommendations and the Model Specifications section for oil capacity.

NOTICE
Too little oil can cause severe engine damage. Too much oil can cause high oil
consumption. Keep the oil level between the high and low level beads (or markings on the
dipstick.

NOTICE
Do not fill the oil through the oil check port (where the dipstick is located) as oil canl
backup in the tube.

11. Check the oil level and add or drain oil as necessary.
12. Reinstall service doors on generator sets that have a sound shield.
13. Reconnect the negative battery cable.
14. Run the generator set for a few minutes, shut it down, and recheck for proper oil level and leaks.
15. Dispose of the used oil and oil filter in accordance with local environmental regulations.

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[Link] Oil Filter

No. Description No. Description

1 Dust Seal 4 O-ring Seals
2 O-ring Sealing Surfaces 5 Filter Header
3 Filter element

FIGURE 8. OIL FILTER

3.5 Maintaining the Fuel System

Keep dirt, water, and other contaminants from entering the fuel system and corroding or clogging fuel
system components.

3.5.1 Fuel Recommendations

WARNING
Combustible Fuel
Diesel fuel is combustible and can cause severe personal injury or death.
Do not smoke near fuel tanks or fuel-burning equipment or in areas sharing ventilation with such
equipment.
Keep flames, sparks, pilot flames, electrical arcs and switches, and all other sources of ignition
well away. Keep a multiclass fire extinguisher available.

High quality Grade 2-D diesel fuel is necessary for good performance and long engine life. Use Grade 1-D
diesel fuel where ambient temperatures are below 5° C (40° F). Where fuel is exposed to cold ambient
temperature, use fuel that has a cloud point (temperature at which wax crystals begin to form) at least 6°
C (10° F) degrees below the lowest expected fuel temperature.
• Diesel fuels specified by EN 590 or ASTM D975 are recommended.

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• The Cetane number should not be less than 45 and sulfur content not more than 0.5% by weight.
• The specifications for the type and sulfur content (ppm, % weight) of the diesel fuel used must
comply with all emissions regulations applicable where the generator set is to be operated.
• Diesel fuel must meet the ASTM D975 standard for lubricity and pass a minimum load level of 3100
grams as measured by ASTM D6078, or maximum scar diameter of 0.45 mm as measured by
ASTM D6079 or ISO 12156-1.
• B5 bio-diesel fuel that meets industry specifications and quality is suitable for use with this generator
set.

[Link] Bio-Diesel Fuels B5-B20

B5 bio-diesel fuel that meets industry specifications and quality is suitable for use with this generator set.
See the Specifications Table Chapter 9 on page 159 for model and spec compatibility of bio-diesel
blends up to B20.
Before using bio-diesel fuel blends ensure the following:
• The vehicle propulsion engine is capable of using B20 when sharing the same fuel tank.
• The OEM has installed a B20 compatible fuel line from fuel tank to generator set.
• The OEM has installed a water separator in the fuel line just before the generator set.
Approved Bio-Diesel Fuel:
• Bio-diesel meeting either ASTM D6751 or EN14214. Fuel meeting either ASTM D6751 or EN14214
can be blended with an acceptable diesel fuel meeting ASTM D975, meeting ASTM D975 up to 20
percent volume concentration (B20).
Blended bio-diesels fuels should be bought pre-blended and not made by customers.
Bio-Diesel Properties:
• Bio-diesel has poor oxidation stability which can accelerate fuel oxidation. Fuel oxidation can reduce
generator performance. This effect is accelerated at increased ambient temperatures.
• Bio-diesel properties change at low ambient temperatures (below 235 °F/-55 °C). Necessary
precautions must be taken when operating the generator with bio-diesel blends in low ambient
temperatures, such as a fuel heater, hose insulation, or additional anti-gel fuel additives.
• Bio-diesel fuel blends are an excellent medium for microbial growth. Microbes cause fuel system
corrosion and premature filter plugging. The effectiveness of all commercially available conventional
anti-microbial additives, when used in bio-diesel, is not known. Consult your fuel and additive
supplier for assistance.
• It is highly recommended that specific market applications are avoided or exercised with extra care
due to some of the properties of bio-diesel fuel blends such as cold weather operation, long term
storage, material incompatibilities and other effects on engine operating characteristics. Such
applications that should use standard fuels include applications that experience seasonal usage,
storage for periods exceeding 60 days, and extreme temperatures or humidity.
Storage Requirements:
If using bio-diesel for seasonal applications (stored more than 90 days), the generator must be purged
before storage by running the engine on pure diesel fuel meeting ASTM D975 for a minimum of 30
minutes.
Warranty Coverage:

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Cummins Warranty covers failures that are a direct result of defects in material or factory workmanship.
Generator damage, service issues and/or performance issues determined by Cummins to be caused by
bio-diesel fuel blends not meeting the specifications outlined in the applicable Installation, Operator, and
Service Manuals are not considered to be defects in material or workmanship and may affect your
generator's warranty.

3.5.2 Draining the Fuel Filter

Drain water and sediment more often than scheduled if fuel quality is poor, condensation cannot be
avoided, or when a WATER IN FUEL warning is being displayed. Check for upstream filters which may
need to be replaced.
Have towels and containers ready to clean, collect, and properly dispose of spilled or dripping fuel.
1. Using an insulated wrench, disconnect the negative (-) cable at the battery to prevent the engine
from starting.
2. Open the front access door.
3. Disconnect the water sensor connector.
4. Loosen the vent and drain screws, drain water and sediment into a suitable container (about 1/2 cup
or 120 ml).
5. Close the drain screws, tighten the vent, and reconnect the water sensor.
6. Replace the front access door.
7. Connect the negative (-) battery cable.
8. Dispose of the drain-off in accordance with local environmental regulations.

3.5.3 Replacing Fuel Filter

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

WARNING
Combustible Fuel
Diesel fuel is combustible and can cause severe personal injury or death.
Do not smoke near fuel tanks or fuel-burning equipment or in areas sharing ventilation with such
equipment.
Keep flames, sparks, pilot flames, electrical arcs and switches, and all other sources of ignition
well away. Keep a multiclass fire extinguisher available.

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See Section 3.1 on page 21 for scheduled filter change. The generator set has a primary and a
secondary fuel filter. The primary filter has a water separator and sensor, see the figure below. Check for
up-stream filters which may also need to be replaced.
Keep dirt, water and other contaminants from entering the fuel system and corroding or clogging fuel
injection components.
To replace the fuel filters:
1. Use an insulated wrench to disconnect the negative (-) cable at the battery to prevent the engine
from starting and close any fuel supply and return valves.
2. Disconnect the water sensor.
3. Clean the area surrounding each filter assemblies to keep debris out of the fuel system and drain the
fuel in each filter into a suitable container by loosening its vent and drain screws. Dispose of the
water, sediment and fuel in accordance with local environmental regulations.
4. Firmly grasp each filter retaining ring, lift it up and rotate it counterclockwise 1/4 turn (as viewed from
below). Remove the ring with its filter element.
5. Install the new filters, properly indexing the raised locators with the mounting base slots.
6. Install the retaining rings, making sure the dust seals are in place. Hand tighten about 1/3 turn until it
audibly snaps into its detent.
7. Reconnect the water sensor.
8. Connect the negative (-) cable at the battery.
9. Manually prime engine with priming lever on mechanical fuel pump to fill the new filter. If generator
set has optional electric fuel pump, prime engine for at least 30 seconds to fill new filters. Run the
generator for a few minutes and check for leaks, shut down the generator immediately if there is a
leak. Repair leak before starting generator set.

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No. Description No. Description

1 Retaining Rings 3 Connector on Water Sensor
2 Primary Filter Vent and Drain 4 Secondary Filter Vent and Drain

FIGURE 9. PRIMARY AND SECONDARY FUEL FILTERS

3.5.4 Priming the Fuel System

WARNING
Combustible Fuel
Diesel fuel is combustible and can cause severe personal injury or death.
Do not smoke near fuel tanks or fuel-burning equipment or in areas sharing ventilation with such
equipment.
Keep flames, sparks, pilot flames, electrical arcs and switches, and all other sources of ignition
well away. Keep a multiclass fire extinguisher available.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns.
The unit is to be installed so that the risk of hot surface contact by people is minimized. Wear
appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

The fuel system should be primed after fuel filters are replaced or after the generator set runs out of fuel.

[Link] Priming with Mechanical Fuel Pump

The engine is equipped with a cam-driven mechanical pump with a manual priming lever that is pushed up
and down to pump fuel. If the priming lever cannot be pushed down, crank the engine over once to turn
the internal cam lobe to the low side and thus free up the lever.

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Before priming, loosen the secondary filter vent to allow air to escape while priming. Close the vent when
the filter is full.

No. Description No. Description

1 Secondary Filter Vent 3 Priming Lever
2 Primary Filter Vent

FIGURE 10. PRIMING FUEL

[Link] Priming with Optional Electric Fuel Pump

If the generator set is equipped with a supplementary electric fuel pump, press and hold the control switch
or digital display Stop/Prime button to fill the fuel lines and filters. The fuel pump starts in about 2
seconds.
If both filters need to be filled, loosen both filter vents to allow air to escape while priming. Close the
primary filter vent when the primary filter is full and the secondary filter vent when its filter is full.

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FIGURE 11. ELECTRIC FUEL PUMP

[Link] Bleeding the Injector Lines

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

It may be necessary after replacing parts or running out of fuel to bleed the air trapped in the fuel lines
between the fuel pump and injectors. For all models, to bleed air from the fuel line, loosen the connection
at the injection nozzle (see Figure 12) using two open-end wrenches to avoid damaging the nozzle
assembly.

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FIGURE 12. BLEEDING THE INJECTOR LINES

3.6 Maintaining the Cooling System

The engine is cooled by a pressurized, closed-loop liquid system. Coolant is pumped through passages in
the engine block, head, and exhaust manifold. The exhaust manifold also serves as the engine coolant
reservoir.
Raw water (flotation water) is pumped through tubes in the heat exchanger to cool the engine coolant.
The raw water then passes through a hose into the exhaust-water mixer where it cools the exhaust gases
and is expelled.

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3.6.1 Cooling System Components

No. Description No. Description

1 Coolant Hose 7 Coolant Hose
2 Drain Cock 8 45 Degree Elbow
3 Drain Cock 9 Coolant Hose
4 Coolant Hose 10 Water Pump
5 45 Degree Elbow 11 45 Degree Elbow
6 Water Pump Gasket

FIGURE 13. COOLING SYSTEM COMPONENTS

3.6.2 Pressure Cap

WARNING
Hot Coolant
Hot coolant is under pressure and can spray, causing severe burns when loosening the pressure
cap or opening the coolant drain.
Let the engine cool before loosening the pressure cap. Wear safety glasses.

Replace the pressure cap every two years (seals deteriorate and leak). Proper cooling system pressure (7
psi) is essential for optimal engine cooling and minimal coolant loss.

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3.6.3 Coolant Hoses

Check for and replace hoses that leak or are damaged.
Make sure the two hoses from the recovery tank are routed through the two holes in the right side of the
generator set enclosure (if applicable), that the coolant recovery hose is connected to the fill neck on the
engine, and that the overflow hose terminates in the drip pan where it does not splash coolant on
electrical components.

3.6.4 Siphon Break

NOTICE
Bypassing a siphon break or failing to maintain it can lead to engine flooding and damage to the
engine that is not covered under warranty.

A siphon break is installed when the exhaust-water mixer is less than 6 inches above the water line.
Replace the siphon break if it is encrusted with deposits, which indicates leakage. If it is of the bleed-vent
type, check that the vent hose is connected to a through-hull fitting. Check for normal water flow whenever
the engine is running. See the Installation Manual for more information regarding siphon breaks.

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No. Description No. Description

1 Hose 4 Clamp-Hose
2 Valve-Check 5 Connector-Hose
3 Cap-Tube 6 Side Marked Vac (Black)

FIGURE 14. SIPHON BREAK

3.6.5 Coolant Recommendations

WARNING
Toxic Hazard
Ethylene glycol, used as an engine coolant, is toxic to humans and animals.
Wear appropriate PPE. Clean up coolant spills and dispose of used coolant in accordance with
local environmental regulations.

Use a high quality, fully formulated, ethylene glycol coolant with rust inhibitors and coolant stabilizers that
meets ASTM D6210 Standard Specification for Fully-Formulated Glycol Base Engine Coolant for Heavy-
Duty Engines. This provides corrosion protection, foam control, liner-pitting protection, and scale/deposit
control.

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Unless prohibited by shipping regulations, the generator set is shipped with the recommended 50/50
mixture of water and ethylene glycol which provides protection to -37° C (-34° F). In warmer climates and
sea water environments, a 60/40 mixture of water/ethylene glycol is recommended.
Use fresh water that is low in minerals and corrosive chemicals for the coolant mixture. Distilled water is
best.
Seethe Model Specifications section regarding coolant capacity.

3.6.6 Replenishing Normal Coolant Loss

Check coolant level in the recovery tank before the first startup of each day and, if necessary, refill to
COLD when the engine is cold or to HOT when it is running. The recovery tank is designed to maintain
coolant level, not to fill the system. If the tank is empty, check for and repair any coolant leaks and refill
the system through the fill neck on the engine.
Make sure the two hoses from the recovery tank are routed through the two holes in the right end of the
generator set enclosure, that the coolant recovery hose is connected to the fill neck on the engine, and
that the overflow hose terminates in the drip pan where it does not splash coolant on electrical
components.

3.6.7 Refilling the Cooling System

NOTICE
Filling a hot engine with cold water can cause cracks in the manifold, head, and block. Follow the
manufacturer's instructions for cleaning and flushing.

NOTICE
Low coolant level can cause severe engine damage. Be sure the system is full.

See Section 3.6.5 on page 41 for coolant specifications. See the Model Specifications section for coolant
capacity.
1. Close the block and heat exchanger drain valves (or check to be sure they are closed), reconnect
the pump inlet hose (or check to be sure it is connected), and fill the system through the engine fill
neck. The system fills only as fast as the air can escape. Fill to the bottom of the fill neck.
2. Start and run the engine for a couple of minutes to dislodge air pockets then shut it down.
3. Check the coolant level, add as much coolant as necessary, and secure the pressure cap.
4. Refill the recovery tank up to the COLD mark.
5. On sets with an enclosure, secure the top and front access doors, and use an insulated wrench to
reconnect the battery cables, negative cable (-) last, when done.

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[Link] Coolant Fill Vent Cock

No. Description No. Description

1 Coolant Fill 2 Vent Cock

FIGURE 15. COOLANT FILL VENT COCK

3.6.8 Draining and Cleaning Cooling System

WARNING
Hot Coolant
Hot coolant is under pressure and can spray, causing severe burns when loosening the pressure
cap or opening the coolant drain.
Let the engine cool before loosening the pressure cap. Wear safety glasses.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

NOTICE
Filling a hot engine with cold water can cause cracks in the manifold, head, and block. Follow the
manufacturer's instructions for cleaning and flushing.

1. Have towels and containers ready to clean, collect and properly dispose of the coolant.
2. Use an insulated wrench to disconnect the negative (-) cable at the battery to prevent the engine
from starting, let the engine cool, remove the front access door, top of the enclosure and coolant
pressure cap.
3. Remove the pressure cap.

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4. Remove heat exchanger drain plug. Disconnect and drain lower hoses. Open block drain valve.
Drain the coolant into suitable containers for disposal in accordance with the local regulations for
hazardous substances.
5. Drain or flush a keel cooler in accordance with the manufacturer's instructions.
6. Use radiator cleaning chemicals to clean and flush the cooling system before refilling with fresh
coolant. Follow the cleaner manufacturer's instructions.

3.6.9 Heat Exchanger

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

NOTICE
Ethylene glycol is considered toxic. Do not use it to protect the raw water passages in the heat
exchanger from freezing. It is expelled into the environment when the generator set is started.

See Section 3.1 on page 21 for scheduled maintenance. Clean the raw water tubes if the engine keeps
shutting down (Code No. 1) or the engine gauge or digital display indicates abnormally high engine
temperatures. Drain the heat exchanger if there is a danger of freezing when the generator set is not
running or is in storage. Freezing water can damage the raw water tubes in the heat exchanger. Engine
coolant is protected from freezing, water is not.

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[Link] Heat Exchanger

No. Description No. Description

1 Zinc Anode 3 Front End Cap and O-rings
2 Rear End Cap and O-rings 4 Heat Exchanger

FIGURE 16. HEAT EXCHANGER

3.6.10 Removing and Installing the Heat Exchanger

Removal
1. Remove the rear doors and the top and end panels, if so equipped.
2. Have towels and containers ready to prevent spilling raw water on the electrical components below
the heat exchanger.

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3. Drain enough coolant so that it does not spill out when the heat exchanger is withdrawn.
4. Disconnect the connector on the raw water flow switch on the front end cap.
5. Disconnect the raw water hoses from the front and rear end caps.
6. Remove the heat exchanger.
Installation
1. Lubricate the 4 O-rings (2 each end) with multi-purpose grease.
2. Install the small O-rings in the bore groove of the end cap.
3. Install the larger O-rings in the face groove.
4. Install the rear end cap and mounting screws leaving a 6 mm (1/4 inch) gap. Make sure the hose
barb points in the correct direction.
5. Install the front end cap with the heat exchanger properly seated in the bore. Make sure the hose
barb points in the correct direction.
6. Evenly tighten the front end cap screws until the end cap touches the housing.
7. Evenly tighten the rear end cap screws until the end cap touches the housing.
8. Tighten the end cap mounting screws to 24 N-m (18 ft-lb).
9. Reconnect the hoses and switch connector.

3.6.11 Draining and Cleaning the Heat Exchanger

1. Remove the front end cap and rear end caps.
2. Inspect the heat exchanger and clean it thoroughly. Use a 4.76 mm (3/16 inch) diameter brass rod to
clean the full length of each tube.
3. Inspect the zinc anodes and replace if necessary.
4. Inspect the O-rings and replace if necessary.
5. Have the heat exchanger core pressure tested if you think it might be defective. Replace it if
necessary.
6. Reassemble all the parts that were disassembled for access.

3.6.12 Zinc Anode

Replace the zinc anode as recommended in Chapter 3 on page 21. Use thread sealant on the zinc plug
and drain plugs and replace the clean-out cover gaskets if the old ones are torn or otherwise damaged.
See Section 3.6.9 on page 44 for location of zinc anode.

3.6.13 Replacing the Thermostats

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

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WARNING
Hot Coolant
Hot coolant is under pressure and can spray, causing severe burns when loosening the pressure
cap or opening the coolant drain.
Let the engine cool before loosening the pressure cap. Wear safety glasses.

See the Section 3.1 on page 21 section for scheduled replacement. The two thermostats are a matched
pair and must be replaced as a pair.
1. Use an insulated wrench to disconnect the negative battery cable at the battery to prevent the engine
from starting. Let the engine cool down.
2. Remove the rear door if the generator set has an enclosure.
3. Remove the coolant pressure cap.
4. Drain enough coolant so that it does not spill out when the thermostat housing is loosened.
5. Loosen the coolant hose clamp on the cover (2).
6. Remove the four thermostat housing bolts (1) and pull off the cover (2).
7. Remove the two thermostats (3), and gasket (4). Discard the gasket.
8. Rotate the cover (2) to clean off the gasket area (by rotating the cover, prevents any damage to the
hose through kinking).
9. Clean off the gasket area on the housing (5) and install the new thermostats and gasket. Apply
Three Bond 1215 liquid sealant or equivalent to the top side of the gasket.
10. Replace the cover (2), install the four thermostat housing bolts (1) and tighten the coolant hose
clamp.
11. Replenish any lost coolant (refer to the previous section - Refilling the Cooling System), secure the
pressure cap, secure the top of the enclosure and access door, and reconnect the negative battery
cable.
12. Start the generator set and check for any leaks. Repair any leaks as required.
13. Allow the engine to reach the thermostat operating temperature to make sure the thermostat is
operating correctly.
14. Stop the engine and allow to cool before checking the coolant level. Top up as required.

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FIGURE 17. COOLANT THERMOSTATS

3.6.14 Replacing Raw Water Pump Impeller

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

NOTICE
Do not lubricate with petroleum products like grease and oil which chemically attack impeller
materials.

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See Section 3.1 on page 21 for scheduled replacement. Avoid spilling raw water on the electrical
components below the pump. Have towels and containers ready in case of water spillage.
1. Close the sea-cock.
2. Use an insulated wrench to disconnect the negative (-) cable at the battery to prevent the engine
from starting.
3. Remove the impeller cover, and gasket. An impeller removal tool may be necessary to pull the
impeller off the shaft.
4. Inspect the O-ring for damage. Replace if nessacary.
5. Install the new impeller. Twist the impeller clockwise (the way it normally turns on its own) while
squeezing it into the housing.
6. To provide initial lubrication and better pump suction before water reaches the pump, wet the inside
of the pump and impeller with water, soap solution, or a silicone lubricant and secure the O-ring and
cover.
7. Secure the cover using a new gasket.
8. If the sea water strainer is above the water line, fill it for faster prime and secure its cover.
9. Open the sea-cock, reconnect the negative battery cables, and start the generator set. The generator
set will shut down within 8 seconds if there is no raw water flow, and the amber status lamp will blink
shutdown Code No. 7. If it shuts down, remove any blockage and restart the generator set.

FIGURE 18. RAW WATER PUMP IMPELLER

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3.6.15 Replacing the Serpentine Belt

WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

The serpentine belt drives the battery charging alternator and coolant pump. See Section 3.1 on page 21
for scheduled inspection or replacement.
Replacing the Belt
1. Use an insulated wrench to disconnect the negative (-) cable at the battery to prevent the engine
from starting.
2. Remove the belt guard or enclosure end panel.
3. If the generator set is so equipped, disconnect the PTO shaft. See Section 3.6.16 on page 51.
4. Relieve belt tension by rotating the tensioner pulley arm counterclockwise and remove the belt. Use
a 15 mm wrench on the pulley center screw to rotate the arm.
5. Check the belt tensioner, idler, alternator, and coolant pump pulleys for smooth rotation. Repair or
replace as necessary.
6. Check the arm for smooth operation throughout the arc of its travel between end stops. Repair or
replace as necessary.
7. Install the belt making sure each "V" is in its proper groove in each pulley.
8. Check the position of the tensioner arm. It should be about midway between its end stops. If it is
near or touching either end stop, the belt is too long or too short. Replace the belt as necessary.
9. Replace the belt guard or enclosure end panel.

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No. Description No. Description

1 Battery Charging Alternator 4 Crankshaft
2 Belt Tensioner 5 Coolant Pump
3 Idler

FIGURE 19. SERPENTINE BELT

3.6.16 Disconnecting PTO Shaft

Remove the 4 shaft flange screws and the 4 radial coupling screws and slide the shaft away from the
crankshaft pulley far enough to let the belt through. When reassembling, tighten the flange screws to 75
Nm (54 ft-lb) and the radial coupling screws to 225 Nm (170 ft-lb).

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No. Description No. Description

1 Flange Screws 2 Radial Coupling Screws

FIGURE 20. PTO SHAFT

3.7 Replacing the Air Filter Element

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

NOTICE
Fuels, solvents, cleaners, and detergents can damage the filter media and rubber seals. Only use
hot soapy water to clean the filter element.

The engine is equipped with a washable air filter element. Refer to Chapter 3 on page 21 for scheduled
air filter element cleaning. Inspect and clean the element more often in dusty environments. To service the
filter element:
1. Release the end cap latches and withdraw the filter element.
2. Replace the filter element if the filter media or rubber seals are damaged.
3. Wash the filter element in hot soapy water and let dry thoroughly.
4. Oil the filter element with a suitable air filter oil.

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5. Reinstall the filter element.

FIGURE 21. AIR FILTER ELEMENT

3.8 Replacing the CCV Filter Element

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

WARNING
Hot Surfaces
Contact with hot surfaces can cause severe burns, lacerations and liquid splash.
Wear appropriate PPE when working on hot equipment and avoid contact with hot surfaces.

Refer to Chapter 3 on page 21 for scheduled CCV (Crankcase Vent) filter element replacement. Replace
the filter whenever the red service indicator in the filter header pops up.
1. Remove the CCV housing, withdraw the filter element, and discard it.
2. Install the new filter element making sure the inner and outer O-ring seals seat properly.
3. Reset the red service indicator if it popped up by unscrewing the clear plastic cap, pushing the
indicator back down, and re-installing the cap.

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No. Description No. Description

1 Filter Header 4 Filter Housing
2 Service Indicator 5 Filter Element
3 O-ring Seals

FIGURE 22. CCV FILTER ELEMENT

3.9 Storing the Generator Set

When the generator set cannot be exercised regularly and (or) is idle for more than 120 days, proper
storage is essential in preserving top performance and reliability.
1. Turn off the generator set line circuit breaker or AC distribution panel.
2. Change the engine oil and filter and attach a tag indicating oil viscosity.
3. Crank the engine several revolutions by pressing the start switch momentarily but do not let it start.
This fills the oil passages with the new oil.
4. Use an insulated wrench to disconnect the battery cables, negative [-] cable first, from the starting
battery and store the battery according to the battery manufacturer's recommendations. Check
coolant level and add as necessary. Test the coolant mixture if freezing temperatures are possible
and change if necessary.
5. Drain the heat exchanger and muffler if freezing temperatures are expected.
6. Disengage the PTO clutch, if so equipped.
7. Clean and lightly oil parts that can rust.

3.10 Cold Temperature Storage

Freezing water can damage the heat exchanger and exhaust cooler. Drain these of any water before
freezing temperatures begin. See Section 3.9 on page 54.

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3.11 Returning the Generator Set to Service

1. Check the oil tag on the generator set and change the oil if the viscosity indicated is not appropriate
for the temperatures expected.
2. Use an insulated wrench to reconnect the starting battery, negative (–) cable last.
3. Replace the raw water pump impeller if it is over one year old.
4. Service the air filter element if it is dirty.
5. Reinstall the serpentine belt if so equipped (see Service Manual).
6. Reinstall the PTO clutch, if so equipped.
7. Perform required maintenance.
8. After connecting the battery complete the pre-start checks and prime the fuel system.
9. Start and run the generator set.
10. Turn on the generator set line circuit breaker or distribution panel when ready to power loads.

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4 Generator Set Control
4.1 Overview
WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

The control board has a microprocessor-based controller that provides all the control, monitoring, and
diagnostic functions required to operate the generator set. The generator set controller talks to the engine
control module (ECM), which is engine mounted, through the Network Interface Module (NIM) mounted in
the control box.
Up to three Cummins Digital Displays may be connected to the generator set for operator control and
monitoring. The NIM has a connector for external SAE J1939 data link connections to an integrated boat
monitoring system.
Generator sets equipped for parallel operation have a separate voltage regulator.
Refer to the wiring diagrams Appendix A on page 173and wiring harness drawings Appendix C on page
189 for more information on control board wiring.

4.2 Controller
4.2.1 Major Functions of Generator Set Controller
[Link] Initialization
Control initialization consists of checking memory (RAM, ROM, and EEPROM) and generator set
configuration.

[Link] Fuel Prime

The fuel priming function can be used if the generator set is equipped with an electric fuel lift pump. See
Priming the Fuel System in the Operation Chapter.

[Link] Start
Press and hold the control switch at START (Preheat) until the generator set starts. The Controller:
1. Energizes the fuel lift pump, if so equipped
2. Enables the status lamp (amber) to flash rapidly
3. Enables run relay K6 to power the ECM and NIM and wake the boat monitoring system
4. Enables start relay K7 to signal the ECM to crank the engine
5. Enables some fault detection
6. Enables field flash, except when PMG excited
7. Disables start relay K7 to signal the ECM to discontinue cranking

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8. When operating speed is reached:

a. Enables output voltage, except when PMG excited
b. Turns off field flash
c. Switches amber status lamp to green run lamp.
d. Enables Switched B+ (J1-8)
e. Enables complete fault detection.

[Link] Stop
Touch the control switch to STOP (Prime). The controller:
1. Disables run relay (K6).
2. Disables output voltage, except when PMG excited.
3. De-energizes the fuel lift pump, if so equipped.
4. Turns off the status lamp.
5. Writes session data (number of cranks, minutes of operation, last fault, etc.) to non-volatile memory
(NVM).
6. Removes processor power when idle 5 minutes.

NOTICE
Stop takes precedence over Start if both are present due to a faulty switch or other cause.

[Link] Fuel Control

The controller allows the ECM to control fueling to maintain nominal frequency (speed) as load varies.

[Link] Voltage Regulation - Quad-Winding Excited Generators

The controller maintains nominal AC output voltage by varying field current as load varies. In response to
transient loads it lowers the voltage set-point to allow engine recovery. Field power (DC) is supplied by the
quadrature windings (Q1-Q2) (AC) through the controller. See Section 7.4 on page 125.

[Link] Voltage Regulation - PMG Excited Generators

The voltage regulating function of the controller is disabled. AC output voltage is regulated by a separate
AVR. See Section 7.3 on page 123. Field power is supplied by the PMG.

[Link] Fault Monitoring, Shutdown and Diagnostics

See the Troubleshooting Chapter of this manual (Chapter 8 on page 127).

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4.2.2 Control Block Diagram

FIGURE 23. CONTROL BLOCK DIAGRAM

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4.2.3 Connectors
NOTICE
Makeshift meter test probes used for testing control board connections during troubleshooting
can damage pin sockets by spreading or dislodging the contact wiper arms, resulting in an open
or intermittent electrical connection. Use a mating pin (Cummins PN 323-1491) or a test probe
that is 0.045 inches in diameter. Replace damaged pin sockets (Cummins PN 323-1492). Make
sure the pin sockets are fully seated and cannot be pulled out.

All connections to the controller are through connectors P1/J1 (black), P2/J2 (gray) and P3/J3 (green).
When removing a connector from the controller, squeeze the locking tabs on the sides while pulling out.
When reinstalling a plug, make sure the seal is in place and that the locking tabs snap into position.

4.2.4 Generator Controller Mounting

FIGURE 24. GENERATOR CONTROLLER MOUNTING

4.2.5 Configuring Generator Set Controller Using Digital Display

A replacement controller must be configured to the generator set configuration (1-phase or 3-phase). An
INVALID GENSET CONFIGURATION - CODE NO.37 shutdown occurs at startup if not configured
properly. Also, the digital display hour meter should be set to match the master hour meter.

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Setting Configuration:
1. Stop the generator set and press STOP 6 times to display the configuration screen.
2. Press NEXT to select Genset Config.
3. Press the up-down arrows to select the configuration number marked on the generator set
nameplate, or see table below.
4. Press BACK to save the selection and get back to GEN STATUS.
Setting Digital Display Hour Meter:
1. Press NEXT to select Set Hour Meter.
2. Press the up-down arrows to match the number or hours on the master hour meter.
3. Press BACK to save the selection and get back to GEN STATUS.

FIGURE 25. CONFIGURING CONTROLLER AND SETTING HOUR METER

[Link] Generator Set Configuration Codes

TABLE 2. GENERATOR SET CONFIGURATION CODE OR CODES

Generator Set Model Code Number

MDDCA, MDDCF, MDDCK, MDDCL — 1-Phase 27
MDDCA, MDDCL — 3-Phase 34
MDDCB, MDDCG, MDDCM — 1-Phase 28
MDDCB, MDDCG, MDDCM — 3-phase 35
MDDCC, MDDCN — 1-Phase 29
MDDCC, MDDCN — 3-Phase 36
MDDCD, MDDCH, MDDCP — 1-Phase 31
MDDCD, MDDCH, MDDCP — 3-Phase 37
MDDCE, MDDCJ, MDDCR — 1-Phase 32
MDDCE, MDDCJ, MDDCR — 3-Phase 38
MDDCF, MDDCK — 3-Phase 39

4.2.6 Configuring Generator Set Controller Using Control Switch

1. Remove the insulating connectors from wiring harness connectors CONFIG 1 and CONFIG 2 in the
control box and connect them together. This places the control in configuration mode. (In
configuration mode the control does not start, prime, or display faults.)

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2. The status lamp on the control switch flashes the numeric configuration code, a two-digit number.
See above table for appropriate code number.
3. Press START or STOP to increase or decrease the code number. For example, the lamp should
flash as follows when configured for a 1-Phase, Model MDKDR generator set (15): flash — pause —
flash-flash-flash-flash-flash — long pause — repeat code
4. When configured properly, disconnect CONFIG 1 from CONFIG 2 and re-install the insulating
connectors that were removed from each connector.

4.2.7 Single or Parallel Generator Set Operation Switch

NOTICE
The generator could overheat from high reactive currents if the switch is left in the single
operation position during parallel generator operation.

NOTICE
Voltage regulation could be unstable if the switch is left in the parallel operation position during
single generator operation.

A PMG-excited generator is designed for paralleling applications. A current transformer (CT) is provided to
detect reactive current so that excitation can be regulated between the generators. A switch shorts the CT
circuit for single generator operation.
Parallel Operation - To prepare the generator sets for parallel operation, position the switch on each
generator set to parallel (down).
Single Operation - To prepare a generator set for single operation, position the switch on each generator
set to single (up).

4.2.8 Manual Voltage Control

NOTICE
Improper manual voltage control can lead to equipment damage. You must be trained and use
proper voltage metering. Always turn the voltage adjusting rheostat fully counterclockwise (MIN)
before turning the switch to manual.

Auto Position - The manual voltage control switch must be in auto for normal automatic voltage
regulation.
Off Position - When the switch is off there is no field current to build up AC output voltage.
Manual Position - Always turn the voltage adjusting rheostat fully counterclockwise to MIN before turning
the switch to MANUAL.

4.3 Control Box

The figure below illustrates the components inside the control box. See Appendix A on page 173 and
Appendix B on page 179 for connections to components inside the box.

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No. Description No. Description

1 Optional Control Switch Panel 4 Network Interface Module Board
2 Digital Display 5 Master Hour Meter
3 Emergency Stop DC Circuit Breaker 6 Control Relays (4)

FIGURE 26. CONTROL BOX COMPONENTS

4.4 Control Switch Schematic

The control switch, when located on the generator, is mounted on the control panel. Unsnap the connector
for access to its terminals. See Appendix A on page 173 for connections.
Referring to the figure below, replace the switch if:
• START does not close terminals 2 and 3,
• STOP does not close terminals 1 and 2,
• Green does not light when 12 VDC is applied across terminals 1 (-) and 6 (+),
• Amber does not light when 12 VDC is applied across terminals 1 (-) and 5 (+).

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FIGURE 27. CONTROL SWITCH SCHEMATIC (DS11-STATUS, DS12-RUN)

4.5 Control Relays

To test a relay, apply 12 VDC (or 24 VDC if applicable) across terminals 85-86 (see figure below).
Replace the relay if 30-86 (NO) does not close or 30-87a (NC) does not open, or either does not return to
its normal position when power is removed.
See the drawings in Appendix A on page 173 for relay function.

FIGURE 28. CONTROL RELAY TERMINALS AND SCHEMATIC

4.6 Master Hour Meter (M11)

See Operator Manual for instructions on how to reset the hour meter on the digital display to match the
master hour meter when replacing the generator set controller.

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4.6.1 Master Hour Meter (M11)

FIGURE 29. MASTER HOUR METER LOCATION

4.7 Emergency Stop Switch/Circuit Breaker

The switch/circuit breaker is mounted on the control panel. Disconnect the leads and check electrical
continuity across the two terminals. Replace the circuit breaker if it does not reset, turn on, or turn off. For
easier access to the switch terminals, push out the four plastic buttons that secure the panel and pull the
panel with switch forward.

4.8 Network Interface Module (NIM)

The standard SAE J1939 Data Link J14 connector is for external connections. It mates with a Deutsch® 4-
pin sealed connector receptacle, part number DT04-4P.
The NIM board has an open 12-pin connector socket for external network connections that mates with a
Deutsch® 12-pin sealed connector plug, part number DT06-12S. See illustration below for NIM board
location.
See Appendix A on page 173 for connection information.

NOTICE
For more information on SAE 1939 applications see your Cummins distributor. Cummins
publication D-3315, Supported Messages on SAE J1939, must be used in designing the interface
for monitoring generator set status and diagnostics.

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4.8.1 NIM Mounting Location

FIGURE 30. NIM MOUNTING LOCATION

4.8.2 NIM Configuration Jumpers

The NIM board has 5 jumpers to configure the board for the specific application, as shown below.
• Jumper W1 has no function at this time.
• Jumper W2 is cut when the generator set is ordered for an SAE J1939 or NMEA 2000TM network
application. The jumper must remain uncut when the generator set is ordered for a SmartCraftTM
network application.
• Jumpers W3 and W4 are used to assign the network addresses of the generator sets in a multiple-
generator set installation. To assign an address, cut the jumpers as shown below.

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TABLE 3. J1939 ADDRESSES

Jumper W3 Jumper W4 Address

Not Cut Not Cut 234
Not Cut Cut 158
Cut Not Cut 179
Cut Cut 203

Cut Jumper W5 if the bus termination resistor on this NIM board is not required to terminate the network
bus. (The jumper is cut on a SmartCraftTM board.)

FIGURE 31. NIM CONFIGURATION JUMPERS

4.8.3 Troubleshooting LEDs

NOTICE
The LED indicator lights DS1 and DS3 are not used at this time.

• The NIM must be awake to communicate. To wake up the NIM, press the start switch on the
generator set. The NIM is always be awake when the generator set is running.
◦ If there is no communication activity, it turns itself off in 5 to 10 minutes after the generator set
stops.
• The LED indicator light DS2 flashes very fast when communicating with the generator set.
◦ If it does not, check that the Y-harness is connected to 8-pin connector J10 on the NIM and
generator set remote connector J4 inside the control junction box. See Appendix A on page
173.
• The LED indicator light DS4 flashes approximately once a second when communicating with the
network.
◦ If it does not, check that the network harness is connected to 12-pin connector J11 on the NIM.
If it still does not communicate, troubleshoot the network harness.

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4.8.4 Troubleshooting Network

1. Make sure the NIM has been configured properly with its jumpers.
2. Disconnect the network harness at 12-pin connector J11 on the NIM and measure resistance across
pins 4 and 5 in the mating network harness connector. The resistance should be 60 ohms, indicating
that there is a terminating resistor at each end of the network and that the wiring is intact.
3. Make sure that CAN HI (or CAN +) matches CAN HI on the display and rest of the network.

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5 Engine and Accessories
5.1 Major Engine Service
WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

For engine service beyond that covered in this section, call an authorized John Deere service
representative. The Engine Emissions Label illustrates where the engine serial number plate and options
code label are located on the engine. Information on these labels isrequired when the service call is made.

5.2 ECM and Engine Sensors

The figure below illustrates the engine, ECM (Engine Control Module), and sensors that are connected to
the ECM through the engine wiring harness.
For associated engine diagnostics, see Section 8.5 on page 136 and Section 8.6 on page 141.
Figure 33 on page 71 through Figure 36 on page 74 illustrate the engine sensors connected through the
generator set wiring harness (see Appendix A on page 173).
Also see the control block diagram in the Controller Section of the Generator Set Control Chapter.

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No. Description No. Description

1 Manifold Air Temperature Sensor 12 ECU Engine Connector
2 Fuel Injection Harness Connection 13 Can Terminator Connector
3 Alternator Excitation 14 Remote On/Off Connector
4 29 Amp ECU Fuse 15 Rail Pressure Sensor
5 30 Amp System Fuse 16 PCV/SCV Suction Control Valve
6 TVP (Transient Voltage Protection) 17 Oil Pressure Sensor
7 Water in Fuel Sensor 20 Fuel Temperature Sensor
10 Coolant Temperature Sensor 21 Engine Cam Sensor
11 ECU Connector 22 Engine Crank Sensor

FIGURE 32. ENGINE WITH ECM AND ENGINE SENSORS

5.3 High Exhaust Temperature Switch (S5)

The high exhaust temperature switch is provided on models with wet exhaust and is a normally-closed
switch. It is secured to the side of the water/exhaust mixer. See Appendix A on page 173 for
connections.

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5.3.1 High Exhaust Temperature Switch

FIGURE 33. HIGH EXHAUST TEMPERATURE SWITCH

5.4 Low Coolant Level Switch (S3)

When provided, the low coolant level switch is threaded into the coolant reservoir. Use thread sealant and
engage at least two full threads when installing. See Appendix A on page 173 for connections.

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5.4.1 Low Coolant Level Switch (S3)

FIGURE 34. LOW COOLANT LEVEL SWITCH

5.5 Raw Water Flow Switch (S6)

This switch is provided on models having a heat exchanger. The raw water flow switch is threaded into the
heat exchanger. It is a normally-closed switch. Use thread sealant and engage at least two full threads
when installing.
Check continuity across the switch terminals while blowing into it (1 psi). Replace the switch if it does not
open and close.
See Appendix A on page 173 for connections.

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5.5.1 Raw Water Flow Switch (S6)

FIGURE 35. RAW WATER FLOW SWITCH

5.6 Low/High Oil Level Gauge

If necessary, readjust the oil level gauge as follows:
1. Add or drain oil as necessary so that the level indicated on the dip stick is as illustrated below.
2. To make sure the engine starts, adjust the gauge level indicators so that the left indicator (high oil
level) is well above the oil level in the gauge and the right indicator (low oil level) well below.
3. Start the generator set and adjust the left level indicator down into the oil. The generator set should
shut down on Code No. 6-OIL LEVEL HIGH OR LOW. Reset the control and adjust the level
indicator up well out of the oil.
4. Repeat the Step 3 procedure with the right indicator. The generator set should shut down on Code
No. 6-OIL LEVEL HIGH OR LOW when the right level indicator rises above the oil level in the gauge.
5. Make necessary repairs or reconnections if the generator set does not shut down when either high or
low oil level is simulated (Steps 3 and 4). For connections see Appendix A on page 173.
6. Stop the generator set and allow oil to drain back into the oil pan. Check the oil level on the dip stick
again and add or drain oil as necessary.
7. Adjust the high oil level indicator (left) to 1/4 inch (6 mm) above the oil level in the gauge and the low
oil level indicator (right) to 1-1/4 inch (31 mm) below.

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No. Description No. Description

1 Fill to this Point 2 Caution Label

FIGURE 36. ADJUSTING OIL LEVEL GAUGE

5.7 Starter and Start Solenoid

The figure below illustrates starter and start solenoid K8 installation. For connections to the starter and
solenoid terminals shown, see Appendix A on page 173.
To test the start solenoid and starter:
1. Service the battery as necessary and clean and tighten connections.
2. Remove the two engine harness leads (red) from start solenoid K8.
3. Apply battery voltage across terminals 85 and 86. The engine should crank normally. If not, go to
next step.
4. Check for battery voltage across terminals 30 and 87.
• Replace the solenoid if it does not close across terminals 30 and 87 when energized.
• Replace the starter if it does not crank when battery voltage is applied. When replacing a
starter, torque the 3 starter motor cap screws to 75 Nm (54 ft-lb).
• Call an authorized John Deere service representative if the start solenoid and starter function
normally but the engine does not crank under ECM control.

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No. Description No. Description

1 12 or 24 Volt Negative Ground Starter 3 24 Volt Start Solenoid
2 12 or 24 Volt Isolated Ground Starter 4 12 Volt Start Solenoid

FIGURE 37. TYPICAL STARTER INSTALLATIONS

5.8 Battery Charging Alternator

Before replacing the alternator:
1. Check the output cable for damage.
2. Check that connections are tight on both ends (terminal on back of alternator and B+ terminal on
starter solenoid).
3. Check that the sense lead from the engine harness is connected.
To remove the alternator:
1. Disconnect it from the output lead and engine harness lead.
2. Remove the belt using a 1/2 inch drive ratchet on the belt tensioner.
3. Remove the bracket screw and hinge bolt.
4. Note the locations of the spacer washers and bushings for reassembly (see figure below).
5. If the front mounting plate was removed, note figure below for screws to tighten first and respective
torques.

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No. Description No. Description

1 Torque pulley nut to 80 Nm (60 ft-lb). 3 If mounting plate was removed, tighten these two
cap screws first and torque to 35 Nm (26 ft-lb). Then
torque the rest to 70 Nm (52 ft-lb).
2 Plain bolt bushing in front foot. 4 Bolt bushing with flange pointed rearward.

FIGURE 38. BATTERY CHARGING ALTERNATOR

5.9 Electric Fuel Pump

NOTICE
Use a backup wrench when connecting or disconnecting fuel lines to prevent damage to the
fittings.

To test the pump.

1. Disconnect its outlet hose from the generator set fuel inlet fitting and connect it to a pressure gauge.
2. Push and Hold STOP (Prime) to prime the fuel system (the amber lamp comes on in 2 seconds to
indicate priming).
3. Replace the pump if the gauge indicates less than 69 kPa (20 psi).
4. For connections see Appendix A on page 173.

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FIGURE 39. ELECTRIC FUEL PUMP

5.10 Mechanical Fuel Pump

5.10.1 Vacuum/Pressure Tests
NOTICE
Use a backup wrench when connecting or disconnecting fuel lines to prevent damage to the
fittings.

1. Disconnect and cap the fuel lines.

2. Connect a vacuum/pressure gauge to the inlet.
3. Push the priming lever all the way down and release. The gauge should indicate the same value
each time and very slowly return to zero. If not, the pump is defective.
4. Connect the gauge to the outlet.
5. Push the priming lever all the way up and release. The gauge should initially indicate 28 to 41 kPa (4
to 6 psi) and very slowly return to zero. If not, the pump is defective.

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5.10.2 Leakage Test

1. Connect a source of compressed air to the inlet fitting regulated to not more than 140 kPa (20 psi).
2. Plug the outlet and submerge the pump in clean diesel fuel.
3. Replace the pump if there are any air bubbles.

5.10.3 Removing Pump

Removing Pump:
1. Disconnect and cap the fuel lines.
2. Remove the two cap screws and withdraw the pump. Cover the opening in the block to keep out
debris.

NOTICE
The pump is driven by a push rod that rides on an eccentric camshaft lobe. It can only be
removed by removing the cylinder head.

3. Inspect the pump lever for wear. Replace the pump if the face is worn flat or concave.

FIGURE 40. MECHANICAL FUEL PUMP

5.10.4 Installing Pump

1. Install the pump, using a new O-ring, with the pumping lever resting on top of the push rod.
2. Apply LOCKTITE® 242 to the screw threads and torque to 30 Nm (22 ft-lb). Do not allow the sealant
to get into the fuel system.
3. Bleed air as instructed in Section [Link].

5.11 Adjusting Valve Lash

Valve lash must be checked and adjusted when the engine is cold. Readjust to the specified Setting in the
table below if valve lash falls outside the Acceptable Range.

TABLE 4. VALVE LASH SPECIFICATIONS

Intake Exhaust
Acceptable Range 0.31 to 0.38 mm (0.012 to 0.015 inch) 0.41 to 0.48 mm (0.016 to 0.019 inch)
Setting 0.36 mm (0.014 inch) 0.46 mm (0.018 inch)

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NOTICE
Inspect the valve tips and rocker arm contact pads for wear. Check all parts for excessive wear,
breakage and cracks. Replace parts that show visible damage. Rocker arms that are unusually
loose should be inspected more thoroughly for damage.

1. Remove the rocker arm cover (Figure 41).

2. Move the CCV bracket out of the way for access to the engine rotation tool and timing pin holes
(Figure 42). If it is necessary to disconnect the fuel lines, make sure the appropriate fuel valves are
closed.
3. Using flywheel rotating tool JDE81-1 rotate the engine flywheel in the running direction (clockwise
viewed from the front) until the No. 1 cylinder is at TDC on the compression stroke. Insert timing pin
tool JDG1571 in the flywheel.

NOTICE
If the No. 1 cylinder rocker arms are loose, the No. 1 cylinder is at TDC on compression. If
they are tight, rotate the engine one full revolution. This is position (B) in Figure 43 below.

4. Check valve lash at each of the rocker arms the arrows point to in position (B) in Figure 43, as
appropriate. Readjust each valve as instructed in Step 6, if necessary.
5. To check the rest of the valves, rotate the engine one full revolution and lock the flywheel with the
timing pin. This is position (C). Check each rocker arm an arrow points to and readjust as instructed
in Step 6, if necessary.
6. To adjust a valve, loosen rocker arm adjusting screw jam nut (A), Figure 44. Turn the adjusting
screw until the feeler gauge slips with a slight drag. Hold the adjusting screw from turning with a
screwdriver and tighten the jam nut to 27 Nm (20 ft-lb). Recheck lash and readjust as necessary.
7. Reinstall the rocker arm cover. Replace cover sealing ring (D), Figure 41, if necessary.
8. Secure the CCV bracket and fuel lines and open any fuel valves that were closed.

FIGURE 41. ROCKER ARM COVER

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No. Description No. Description

1 Remove plastic cover in rotation and timing holes. 2 Move CCV/fuel fitting bracket out of the way.

FIGURE 42. ENGINE ROTATION AND TIMING PIN HOLES IN FLYWHEEL HOUSING

No. Description No. Description

A To Front of Engine E Exhaust Valve
B No. 1 Piston @ TDC Compression I Intake Valve
C No. 4 Piston (left graphic) No. 6 Piston (right
graphic)

FIGURE 43. ROCKER ARM FOR 4 CYLINDER ENGINES (LEFT SIDE) AND 6 CYLINDER ENGINES (RIGHT
SIDE)

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FIGURE 44. SETTING SCREW JAM NUT

5.12 Replacing Fuel Injection Nozzles

5.12.1 Removing Injection Nozzles
Before removing injection nozzles:
• Thoroughly remove all dirt from the cylinder head around the fuel injection nozzles.
• Clean with compressed air to prevent dirt from entering the cylinders.
• Plug the bore in the cylinder head after each nozzle has been removed.
• Cap fuel line openings as soon as they are disconnected.
• Immediately fit protective caps over the nozzle tips and the line connections to avoid handling
damage and getting debris in the fuel system.
• Do not bend the fuel delivery lines, as this could affect their durability.
• When loosening a fuel pressure line, hold the male union of the nozzle line stationary with a backup
wrench.
Removal of injection nozzles:
1. Loosen tube nuts (A), Figure 45, at each nozzle to remove the leak-off lines and T-fittings as an
assembly.
2. Disconnect the fuel injection line from the nozzle using a backup wrench on the nozzle connection as
shown in Figure 46.
3. Remove the cap screw the secures the nozzle in the cylinder head nozzle bore.
4. Pull the injection nozzle out of the cylinder head using nozzle pulling tool JDG1515-1, (A) in Figure
47.

CAUTION
Do not use screwdrivers, pry bars, or similar objects, as they could damage the injection
nozzle beyond repair.

5. Clean the injection nozzle bore using nozzle bore cleaning tool JDE39, (A) in Figure 48. Blow debris
from the hole with compressed air and plug the hole to prevent entry of debris.

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CAUTION
To prevent dulling the cleaning tool, always turn it clockwise, even while pulling it from the
bore.

FIGURE 45. LOOSENING FUEL LEAK-OFF LINES

FIGURE 46. LOOSENING FUEL INJECTION LINES

FIGURE 47. REMOVING INJECTION NOZZLE

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FIGURE 48. CLEANING INJECTION NOZZLE BORE

5.12.2 Installing Injection Nozzles

Installation of injection nozzles:
1. Clean the nozzle bore in the cylinder head if that has not been done. See step 5 in Section 5.12.1
on page 81.
2. Install the nozzle assembly in the cylinder head bore using a slight twisting motion as the nozzle is
seated in the bore (see figure below).
3. Align the nozzle clamp and install the cap screw. Do not tighten the screw yet.
4. Connect the fuel pressure line to the nozzle. Leave the connection slightly loose until air is bled from
the system.
5. Tighten the nozzle hold-down clamp screw to 40 Nm (30 ft-lb).
6. Install the leak-off assembly. Torque the nuts to 5 Nm (3.7 ft-lb) (44 in-lb).
7. Bleed air as instructed in Section [Link] .

5.13 Coolant Pump

WARNING
Hot pressurized coolant.
The failure to properly replace coolant caps can result in hot pressurized coolant escaping from
the radiator fill necks, causing severe personal injury and engine damage.
Make sure the radiator cap is properly secured before operating the generator set.

5.13.1 Removing Pump

1. Drain the coolant.
2. Remove the belt guard or front of sound enclosure.
3. Remove the serpentine belt.
4. Remove the pump inlet elbow (Figure 49).

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5. Remove the pump (Figure 50).

6. Remove the pulley from the pump.

FIGURE 49. PUMP AND INLET ELBOW

FIGURE 50. COOLANT PUMP

5.13.2 Installing Pump

1. Clean the mating gasket surfaces.
2. Install the coolant pump insert from the pump kit, if necessary. Follow the instructions in the kit.
3. Remove the serpentine belt.
4. Install the pump with a new gasket. Torque the cap screws to 16 Nm (12 ft-lb).
5. Install the pulley. Torque the cap screws to 15 Nm (11 ft-lb).
6. Using a new O-ring seal, install the inlet elbow. Torque the cap screws to 35 Nm (26 ft-lb).
7. Refill the system with coolant (Section 3.6.7 on page 42).

NOTICE
Clean and flush the coolant system whenever replacing the pump or timing gear cover.

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5.14 Auxiliary Drive

The engine is equipped with the auxiliary drive only when a raw water pump is provided. To remove the
drive and pump as a unit:
1. Disconnect the oil line.
2. Remove the two cap screws.
3. Look for cracks in the housing and worn or damaged bearings, gears, and splines.
4. Replace if necessary.
When installing an auxiliary drive:
1. Use a new gasket.
2. Torque the cap screws to 95 Nm (70 ft-lb).
3. Reconnect the oil line.

FIGURE 51. AUXILIARY DRIVE AND RAW WATER PUMP

5.15 Raw Water Pump

The engine is equipped with a raw water pump only on models with wet exhaust or wet exhaust and heat
exchanger.
See Replacing the Raw Water Pump Impeller Section in the Maintenance Chapter for instructions on how
to replace the impeller.
To remove the pump:
1. Remove the two cap screws.
2. Look for cracks in the housing, worn or damaged bearings, and signs of water leakage.
3. Replace if necessary.
4. When installing a pump, use a new gasket.
5. Torque the cap screws to 55 Nm (41 ft-lb).

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5.16 Timing Gear Cover Gasket

WARNING
Hot pressurized coolant.
The failure to properly replace coolant caps can result in hot pressurized coolant escaping from
the radiator fill necks, causing severe personal injury and engine damage.
Make sure the radiator cap is properly secured before operating the generator set.

5.16.1 Removing Timing Gear Cover

1. Remove the serpentine belt.
2. Drain engine oil and coolant.
3. Remove the oil pan.
4. Remove the battery charging alternator and bracket.
5. Disconnect the coolant return tube or hose from the pump inlet.
6. Remove the engine speed sensor (Figure 32 on page 70).
7. Remove the auxiliary drive, if so equipped (Section 5.14 on page 85), or the close off plate.
8. Remove the crankshaft pulley or pulley/damper (Section 5.19.2 on page 92 step 7).
9. Remove the stud nuts and cap screws around the border of the timing gear cover (Figure 52).
10. Drive the crankshaft oil seal out of the cover (Section 5.19.1 on page 90).

FIGURE 52. TIMING GEAR COVER AND GASKET

5.16.2 Installing Timing Gear Cover and Gasket

1. Clean the cylinder block and cover gasket surfaces.
2. Clean the timing gear cover in solvent and dry with compressed air.

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3. Inspect the cover for cracks and damage. Make sure the bore for the crankshaft oil seal is clean and
free of nicks.
4. Install the new gasket and cover. Apply LOCTITE® 592 pipe sealant to the capscrews and studs and
torque to 35 Nm (26 ft-lb).
5. Install a new crankshaft oil seal (Section 5.19.2 on page 92).
6. Reassemble all of the other components that were removed.

5.17 Oil Pan Gasket

1. Apply LOCTITE® Flexible Form-In-Place Gasket on the oil pan rail, as shown below, in the four
corners where the timing gear cover and flywheel housing meet the cylinder block.
2. Install the oil pan and new gasket
3. Tighten the cap screws to 35 Nm (26 ft-lb).

No. Description No. Description

1 Oil Pan Rail 3 6-Cylinder Oil Pan and Gasket
2 4-Cylinder Oil Pan and Gasket

FIGURE 53. OIL PAN RAIL, GASKET, AND OIL PAN

5.18 Oil Cooler

WARNING
Hot Oil
Contact with hot oil can cause severe burns.
Avoid direct contact with hot oil. Allow the engine to cool down before carrying out any
maintenance.

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No. Description No. Description

1 6-Cylinder Oil Filter Head 5 Oil Cooler Housing
2 Oil Filter 6 Oil Cooler
3 4-Cylinder Oil Filter Head 7 Coolant Coupling
4 Coolant Drain Plug 8 Coolant Elbow Adapter

FIGURE 54. OIL COOLER ASSEMBLY

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5.18.1 Removing the Oil Cooler

Refer to Figure 54 above.
1. Drain the engine coolant by removing the drain plug on the oil cooler housing.
2. On 6-cylinder engines remove the oil filter header and pull the tubes out of the cover of the oil cooler.
3. Remove the coolant elbow adapter and coupling.
4. Remove the oil cooler housing.
5. Remove the oil cooler from the housing.
6. Inspect the core of the oil cooler for damage, plugging or leakage which would allow oil and coolant
to mix.
7. Back flush the oil cooler to clean all debris from the core.
8. If leakage is suspected, pressure test the oil cooler in liquid with compressed air regulated to 140 to
170 kPa (20 to 25 PSI). Replace the cooler it there are air bubbles. Hold the pressure for at least 30
seconds.
9. Inspect the inside of the oil cooler housing (see figure below). Remove the O-rings (A) and inspect
the surface finish of the O-ring grooves. If ridges are discernible with a finger nail, replace the oil
cooler housing. Do not attempt to repair the oil cooler or housing

FIGURE 55. OIL COOLER HOUSING

5.18.2 Installing the Oil Cooler

1. Install new O-rings lubricated with clean engine oil.
2. Install the cooler in its housing. Apply LOCKTITE® 242 Thread Lock and Sealer to the six Allen head
cap screws and thread them in by hand to secure the core in the housing. Torque the screws to 12
Nm (106 in-lb) in the sequence shown below.
3. Re-install all of the components removed using new gaskets and O-rings.
4. Torque the housing and adapter elbow cap screws to 35 Nm (26 ft-lb).
5. Install the coolant drain plug and torque to 5 Nm (60 in-lb).
6. Refill the cooling system.

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FIGURE 56. TORQUE SEQUENCE

5.19 Front Crankshaft Oil Seal

5.19.1 Removing the Front Oil Seal
1. Remove the pulley (4-cylinder) or pulley/damper (6-cylinder). See Figure 57.

NOTICE
The vibration damper could be damaged if a jaw type puller is used to remove it or it is
dropped or struck with a hammer. For removal, use a heavy duty puller secured to the
auxiliary mounting holes (B).

NOTICE
The vibration damper could suddenly release when the cap screw is removed. Be prepared
to catch it safely to avoid injury or damage to the damper.

a. Insert timing pin tool JDG1571 into the flywheel.

b. Remove cap screw and washer (A) that secure the damper to the crankshaft.
c. Install a thread protector in the nose of crankshaft and secure a heavy duty puller to the pulley
or damper using the auxiliary mounting holes (B). Remove the pulley or pulley/damper.
2. Center punch the oil seal at 12 o'clock and drill a 3 mm (1/8 inch) hole (Figure 58).
3. Remove the oil seal using seal remover tool JD719 (Figure 59).

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FIGURE 57. PULLEY/VIBRATION DAMPER

FIGURE 58. CENTER PUNCH THE OIL SEAL

FIGURE 59. OIL SEAL REMOVER TOOL

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5.19.2 Installing the Front Oil Seal

1. Clean and inspect the seal bore in the timing gear cover (Figure 60). Check for nicks and burrs. Use
a medium grit emery cloth to smooth rough areas.

NOTICE
For proper sealing, the outside diameter of the crankshaft and wear sleeve must be cleaned
with Brake Kleen, Ignition Cleaner, or equivalent and dried prior to installing the seal.

2. Install forcing screw tool JDG954-8 (A) into the nose of the crankshaft until it bottoms (Figure 60).
3. Secure adapter tool JDG954-7 (B) with nut (C) (Figure 60).

NOTICE
For proper sealing, do not allow oil to contact the coating on the outside diameter of the
seal.

4. Apply a light coating of clean engine oil to the lips of the seal and position the seal on the crankshaft
flange. (The spring-loaded side of the seal goes into the timing gear cover first.)
5. Place installer tool JDG954-1 (D) over the adapter. Place guide sleeve tool JDG954-6 (E) over the
installer and seal. See Figure 61.
6. Install the washer and nut onto the adapter and tighten the nut until seal (F) is flush with the face of
the timing gear cover. See Figure 62.
7. Install pulley or pulley/damper as follows:
a. Clean the nose of the crankshaft using LOCKTITE® 7649 clean and cure primer.
b. Apply a light 2 to 3 mm (0.79 to 0.118 inch) bead of LOCKTITE® 680 retaining compound
around the leading edge of the crankshaft nose (Figure 63). Place the pulley or pulley/damper
on the nose of the crankshaft.
c. Dip the mounting cap screw in clean SAE 30 oil and secure the pulley or pulley/damper with
the cap screw and washer. Torque the screw to 500 Nm (369 ft-lb).
d. Remove the timing pin from the flywheel.

FIGURE 60. FORCING SCREW TOOL, ADAPTER TOOL, AND NUT

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FIGURE 61. INSTALLER TOOL AND GUIDE SLEEVE

FIGURE 62. INSTALLED OIL SEAL

FIGURE 63. NOSE OF CRANKSHAFT

5.20 Rear Crankshaft Oil Seal

WARNING
Heavy Load
Incorrect lifting or reposition can cause severe personal injury or death.
Use appropriate lifting methods when removing or repacing the flywheel.

5.20.1 Removing the Rear Oil Seal

1. Separate the engine and generator. See Section 6.10.3 on page 116.
2. Remove the flywheel.

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NOTICE
Discard the old flywheel cap screws when the flywheel is removed and obtain new cap
screws for reassembly.

a. Remove two cap screws and install guide studs (A). See Figure 64.
b. Remove the rest of the cap screws.
c. Pry the flywheel off the crankshaft. Alternatively, insert a punch through the timing pin hole and
tap on it to drive the flywheel from the crankshaft.
3. Adjust the forcing screw (A) on seal remover tool JDG698A so that it centers the tool on the
crankshaft flange. See Figure 65. Using the slots in the seal remover tool as a template, mark three
locations on the seal casing where screws should be installed to remove the seal.
4. Center punch and drill three 4 mm (3/16 inch) holes where marked (Figure 66).

NOTICE
The holes must be drilled near the outer edge of the seal case. The screws pulls the seal
against the wear ring, removing both pieces.

5. Position the tool on the crankshaft. Thread three 62 mm (2-1/2 inch) long sheet metal screws with
washers (B) through the slots of the tool and into the holes drilled in the seal casing (Figure 67).
6. Tighten the forcing screw until the seal is removed.

FIGURE 64. FLYWHEEL

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FIGURE 65. MARKING EXTRACTION SCREW LOCATIONS

FIGURE 66. CENTER PUNCHING AND DRILLING EXTRACTION SCREW HOLES

FIGURE 67. REMOVING REAR OIL SEAL

5.20.2 Installing the Rear Oil Seal

Installation notes:
• The rear oil seal (A) and wear sleeve (B) are fabricated as a non-separable part. See Figure 68.
• To avoid contamination with dirt, do not remove the seal/wear plate assembly from its plastic bag
until just ready to install it.

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• Lubricants of any kind used during installation can cause premature failure of the seal.
• Install the seal with the open side and wear sleeve ID chamfer towards the engine. Reversing the
seal results in oil leakage because crankshaft rotation with respect to the oil seal grooves is wrong.
Installing the seal:
1. Thoroughly clean the OD of the crankshaft flange and bore in the flywheel housing with cleaning
solvent, acetone or other suitable cleaner such as Brake Kleen or Ignition Cleaner and Drier. See
Figure 69.
2. Look for nicks and burrs on the wear ring surface and bore in the flywheel housing. If necessary, use
polishing cloth to remove them. Finish cleaning by wiping with a clean rag.
3. Referring to Figure 70, install pilot JT30041A (A) from seal/wear plate installer tool set JT30040B
using two 38 mm (1-1/2 inch) socket-head cap screws (B). Thread in both cap screws until they
touch the base of the pilot and then back them off 1/2 turn.
4. To line up pilot JT30041A with the crankshaft, slide driver tool JT30042 on over the pilot until it
bottoms. See (A) in Figure 71. Then tighten the two pilot cap screws (B) and remove the driver.
5. Handling the seal carefully, start the seal (B) over the pilot and crankshaft flange with the open side
towards the engine. See Figure 71.

NOTICE
Discard the seal and get a new one if the wear sleeve surface is scratched or gouged or
contaminated with sealant (liquid).

6. Slide driver tool JT30042 (A) back onto the pilot up against the seal. Using a thrust washer and
screw, drive it all the way until it bottoms. See Figure 71.
7. Remove the driver and pilot and check that the seal is properly positioned and square in the flywheel
housing bore.
8. Re-install the flywheel using new capscrews.

WARNING
Heavy Load
Incorrect lifting or reposition can cause severe personal injury or death.
Use appropriate lifting methods when removing or repacing the flywheel.

a. Re-install the guide studs (A) used in removing the flywheel. See Figure 72.
b. Start the cap screws. Do not tighten until the guide studs have been removed and all cap
screws have been started. Tighten the capscrews to138 Nm (102 ft-lb).
9. Reassemble the generator set. See Section 6.11 on page 116 and Section 5.21.

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FIGURE 68. REAR OIL SEAL

FIGURE 69. CLEANING CRANKSHAFT FLANGE AND FLYWHEEL HOUSING BORE

FIGURE 70. REAR OIL SEAL INSTALLER TOOL

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FIGURE 71. INSTALLING REAR OIL SEAL

FIGURE 72. FLYWHEEL

5.21 Generator Set Mounting

See Section 6.10 on page 114 if it is necessary to separate the engine and generator or to remove either
from the skid.
• Torque the mounting screws as specified in table below.
• Make sure to reconnect the skid bonding strap to the generator set grounding point on the engine
flywheel housing when reassembling.

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No. Description No. Description

1 Engine Mounts 3 Generator Mounts
2 Skid Bonding Strap

FIGURE 73. SKID AND VIBRATION ISOLATOR MOUNTS

5.22 PTO Assembly

5.22.1 Clutch Assembly
• The clutch assembly is secured in the PTO bracket with 8 screws (3/8-16). Torque the screws as
specified in the table below.
• The clutch drive plate is secured to the clutch with 4 screws (7/16-14). Torque the screws as
specified in Figure 75 on page 101.
• The clutch leads should exit from the top of the clutch assembly.

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No. Description No. Description

1 Coupler Shown for Reference Only (Installed 2 Torque 3/-16 Mounting Screws (8) to 75 Nm (44 ft-
following clutch installation) lb)

FIGURE 74. CLUTCH ASSEMBLY

5.22.2 PTO Bracket and Coupler

The PTO bracket is secured to the front of the engine with 4 screws. Torque the screws as specified in the
figure below.
To assemble the drive coupler:
1. Slide the drive coupler over the drive adapter and secure the adapter to the crankshaft with 4 flange
screws and torque the screws as specified.
2. Loosely secure the drive coupler to the drive adapter with the 4 radial M16 bolts.
3. Insert the 4 rounded-head bolts into the coupler and thread them into the clutch drive plate. It may be
necessary to tighten the radial bolts to line up the clutch drive bolts with the holes in the drive plate.
4. Torque the 8 coupler bolts as specified when all of the bolts are seated.

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No. Description No. Description

1 Guard 5 Torque (4) Bracket Screws (M16) to 320 Nm (230 ft-
lb)
2 Drive Adapter Torque M10 Flange Screws (4) to 72 6 Clutch Guard
Nm (54 ft-lb)
3 Radial Drive Coupler Bolts (4) Torque to 225 Nm 7 Clutch Drive Plate Torque 7/16-14 Screws (4) to 95
(170 ft-lb) Nm (65 ft-lb)
4 Coupler Drive Plate Screws (4) Torque to 95 Nm (65 8 Drive Coupler
ft-lb)

FIGURE 75. PTO BRACKET, DRIVE ADAPTER, AND COUPLER

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6 Alternator
6.1 Overview
WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

These are 4-pole, rotating-field, brushless, single-bearing generators. Operation is as follows:

1. The engine rotates the generator field (main rotor) to induce output current (AC) in the main stator
windings.
2. Generator output is proportional to the main rotor (field) current supplied by the exciter rotor through
its full-wave rectifier bridge (rotating rectifiers).
3. The generator set controller (Section 4.2 on page 57) rectifies and modulates quadrature winding
output (Q1, Q2) to supply the exciter stator (F1, F2). By comparing generator output voltage with a
reference value, the generator set control regulates field current to maintain nominal output voltage
as load varies. Also, in response to transient loads, it lowers the voltage setpoint to allow for engine
recovery.
4. Residual field magnetism and a permanent magnet in one of the exciter stator poles initiates self-
excitation during startups.
The following tests can be performed without removing the generator.

6.2 Faulty Generator or Regulator Testing

WARNING
Hazardous Voltage
Touching uninsulated live parts inside the generator set and connected equipment can result in
severe personal injury or death.
For your protection, stand on a dry wooden platform or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry from your hands, and use tools with insulated
handles. Secure protective covers when completing installation.

Use the following procedure to isolate AC output problems to the generator or the voltage regulator.
1. Set the line circuit breaker to off and shut down the generator set.

NOTICE
This test involves unregulated excitation of the generator. To prevent damage to the
generator due to overcurrent, make sure that all loads have been disconnected from the
power output terminals of the generator and that all faults have been cleared.

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2. Jumper pins 6 and 7 on connector P12 in the control box to bypass generator set fault shutdown so
that the generator set continues to run during the test. (The boat builder may have connected a
switch for fault bypass operation that can be switched on for the test.)

NOTICE
Do not run this test in fault bypass mode until all engine fault shutdown and pre-alarm
conditions have been serviced. Otherwise engine damage could result that is not covered
by Warranty.

3. Remove the side access cover of the control housing to access the exciter stator leads (X and XX).
Disconnect the X and XX leads from the AC harness (quick connect type connectors).
4. Prepare to measure output voltage across the generator terminals while the generator set is running.
5. Bring two jumpers from a 12 volt battery for connection to the exciter stator X (Field +) and XX (Field
-) leads.
6. Connect the jumper from the positive (+) post of the battery to the X lead. Be prepared to connect
the jumper from the negative (-) post of the battery to the XX lead. If one of the 12 volt cranking
batteries is used, bring the jumpers from the battery connected on the grounded side of the system
to avoid inadvertently imposing 24 volts on the system.
7. Check polarity again. Polarity must be correct or this test can be inconclusive because the induced
and residual magnetic polarities in the exciter stator is opposed.
8. Start the generator set and connect the jumper from the battery negative (-) terminal to the XX lead.
9. The generator circuitry is probably okay if rated output voltage or higher is obtained and the voltages
for all phases are balanced when the exciter is powered by a 12 volt battery. (Normal excitation
voltage ranges from approximately 10 VDC at no-load to approximately 40 VDC at full-load.)
10. If the voltages are unbalanced, troubleshoot the main stator first. If the voltages are uniformly low,
troubleshoot the exciter and field circuits first.
11. When testing has been completed, restore fault protection by switching off the fault bypass switch or
removing the jumper between pins 6 and 7 on connector P12. Make sure the status screen on the
Digital Display does not continue to display "Fault Override" when finished with the work.

NOTICE
Damage to the generator set as a result of bypassing fault shutdown protection is not
covered under Warranty.

6.3 Generator Stator and Rotor Winding Resistances

TABLE 5. GENERATOR STATOR AND ROTOR WINDING RESISTANCES

Model Name Main Winding Quadrature Main Exciter Exciter Stator

Resistance Winding Rotor Winding Rotor Winding Winding
OHMS (1,2) Resistance Resistance Resistance Resistance
OHMS (1) OHMS (+ or - OHMS (+ or - OHMS (+ or -
10%) (1) 10%) (1) 10%) (1)
4-Lead Generators (Single-Phase)
3096-03 0.0578-0.0523 0.361-0.399 0.67 0.180 19.5

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Model Name Main Winding Quadrature Main Exciter Exciter Stator

Resistance Winding Rotor Winding Rotor Winding Winding
OHMS (1,2) Resistance Resistance Resistance Resistance
OHMS (1) OHMS (+ or - OHMS (+ or - OHMS (+ or -
10%) (1) 10%) (1) 10%) (1)
3096-04 0.0368-0.0333 0.296-0.328 0.80 0.180 19.5
3097-02 0.0252-0.0228 0.565-0.624 1.20 0.180 19.5
3097-03 0.0179-0.0162 0.543-0.600 1.31 0.180 19.5
3097-04 0.0137-0.0124 0.459-0.507 1.50 0.189 19.5
12-Lead Generators (Three-Phase)
3096-08 0.0530-0.0480 0.538-0.595 0.67 0.180 19.5
3096-09 0.0341-0.0309 0.453-0.501 0.80 0.180 19.5
3097-07 0.0310-0.0280 0.574-0.635 1.11 0.180 19.5
3097-09 0.0163-0.0147 0.466-0.515 1.31 0.210 19.5
1. If high, recheck winding resistance after the windings have cooled to room temperature.
2. The main windings are probably good if some of the resistances fall outside the range but are all within 10
percent of each other.

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No. Description No. Description

1 Last 6 Digits of Generator Part Number 2 Wheatstone Bridge Tool

FIGURE 76. GENERATOR PART NUMBER AND WHEATSTONE BRIDGE TOOL

6.4 Exciter Stator

6.4.1 Winding Insulation Resistance
Test - Using an ohmmeter, measure resistance between either lead and the stator laminations.
Action - Replace the stator if insulation resistance is less than 1 megohm (1,000,000 ohms).
Disassembly - Disconnect the exciter stator leads X and XX from their connectors in the AC harness and
isolate them from ground.

6.4.2 Winding Resistance

Test - Measure winding resistance with a Wheatstone bridge or digital ohmmeter (See figure below).
Action - Replace the stator if winding resistance is not as specified by the table in Section 6.3 on page
104.

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6.4.3 Exciter Stator Test

No. Description No. Description

1 Measure winding insulation resistance between 2 Measure winding resistance between the two stator
either lead and the stator laminations leads. X and XX.

FIGURE 77. EXCITER STATOR TEST

6.5 Exciter Rotor

6.5.1 Winding Insulation Resistance
Test
Use an ohmmeter to measure resistance between any rotor winding lead, or the terminal to which it is
connected, and the rotor laminations.

Action
Replace the rotor shaft assembly if insulation resistance is less than 1 megohm.

6.5.2 Winding Resistance

Test - With a Wheatstone bridge, measure electrical resistance across each pair of rotor windings: U (CR1
or CR4) and V (CR2 or CR5), V (CR2 or CR5) and W (CR3 or CR6), W (CR3 or CR6) and U (CR1 or
CR4). See Appendix A on page 173.
Action - Replace the whole rotor shaft assembly if the resistance of any winding is not as specified in
Section 6.3 on page 104.
Disassembly - Disconnect the six rotor winding leads from the terminal posts on the rectifier assembly.
See figure below.

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6.5.3 Exciter Rotor

No. Description No. Description

1 Rotor Laminations 3 Rotor Winding Leads
2 Winding Schematic 4 Main Rotor Leads

FIGURE 78. TESTING THE EXCITER ROTOR

6.6 Rotating Rectifiers

The exciter rectifier bridge consists of a positive plate and a negative plate. Each plate contains the
following:
• Three diodes
• Three terminal posts to connect to exciter rotor leads to the diodes
• One terminal to connect to the main rotor (generator field) lead.
A surge suppressor connects between the two plates to prevent damage from transient voltages.
The exciter rectifier bridge is mounted on the exciter rotor, inboard, facing the main rotor (see Figure 79
on page 110).

6.6.1 Diode Test

Inspection
The resistance across each diode should be high in one direction and low in the other direction.

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Disassembly
Disconnect the diode pigtails from the terminal posts.

Test
1. Use an ohmmeter to measure resistance between each diode pigtail and the plate on which the
diode is mounted.
2. Reverse the meter test probes and repeat the tests.

Action
Replace the diode if the resistance is high or low in both directions.

Assembly
Connect the diode pigtails to the terminal posts.

6.6.2 Diode Replacement

Inspection - Make sure the replacement diode is of the correct polarity.
Disassembly - Disconnect the pigtail from the terminal post and unscrew the old diode.
Assembly - Apply heat-sink compound under the head of the diode. Make sure the compound does not
get on the threads. Torque the diodes to 4 to 4.8 Nm (36 to 42 in-lb) and the pigtail terminals to 2.7 Nm
(24 in-lb).

6.6.3 Surge Suppressors

NOTICE
Layers of dust can cause diodes to overheat and fail. Brush dust off the diodes regularly.

Inspection
Inspect for signs of overheating.

Test
Use an ohmmeter to measure resistance in both directions of suppressor.

Disassembly
Remove the suppressor.

Assembly
1. Install the suppressor.
2. Torque the terminals to 2.7 Nm (24 in-lb).

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6.6.4 Testing the Rotating Rectifier Assembly

No. Description No. Description

1 Diode Pigtail (6) 3 Surge Suppressor
2 Terminal (6) 4 Diode Plates (2)

FIGURE 79. TESTING THE ROTATING RECTIFIER ASSEMBLY

6.7 Main Rotor

6.7.1 Winding Insulation Resistance
Test
Use an ohmmeter to measure resistance between any lead of the main rotor windings, or the terminal to
which it is connected, and the main rotor laminations.

Action
Replace the rotor if insulation resistance is less than 1 megohm.

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6.7.2 Winding Resistance

Test - Measure the electrical resistance between the two leads with a Wheatstone bridge or digital
ohmmeter.
Action - Replace the rotor if the resistance is not as specified in Section 6.3 on page 104.
Disassembly - Disconnect the two leads of the main rotor from the terminals on the rotating rectifier
assembly (see figure below).
Assembly - Connect the rotor leads and torque the terminals to 2.7 Nm (24 in-lb) when reassembling.

6.7.3 Testing the Main Rotor

No. Description No. Description

1 Rotor Laminations 2 Main Rotor Leads

FIGURE 80. TESTING THE MAIN ROTOR

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6.8 Main Stator

6.8.1 Winding Insulation Resistance
Test
Use an ohmmeter to measure resistance between any stator lead and the stator laminations.

Action
Replace the stator if insulation resistance is less than 1 megohm.

Disassembly
Disconnect all stator leads and winding taps from their respective terminals. Make sure the lead ends do
not touch the generator frame.

6.8.2 Winding Resistance

Test - Measure electrical resistance across each pair of stator leads (U1-U2, U5-U6, VI-V2, V5-V6, W1-
W2 and W5-W6) with a Wheatstone Bridge having at least 0.001 ohm precision.
Alternatively, winding resistance can be measured line-to-line at the generator terminals (U-V, V-W, W-U)
on star-connected generators. On a 600 volt generator, line-to-line resistance should be twice the table
value (2 winding elements in series). On a series star-connected generator, line-to-line resistance should
be 4 times the table value (4 winding elements in series). On a parallel star-connected generator, line-to-
line resistance should be the same as the table value (2 generator sets of 2 winding elements in series).
Single phase only windings can be measured at W-V and should be twice the table value.
Action - Replace the stator if the resistance of any winding is not as specified in the table in Section 6.3
on page 104.

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6.9 Generator Assembly

No. Description No. Description

1 Drive Discs 7 Enclosure
2 Main Rotor 8 Generator Stator
3 Main Rotor Bearing 9 Installation Mounting Foot
4 Rotating Diode Assembly 10 Exciter Stator
5 Cooling Fan 11 End Plate
6 Fan Guard Stator Leads (not shown)

FIGURE 81. GENERATOR ASSEMBLY

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6.10 Generator Disassembly

6.10.1 Air Baffle Removal
When removing a generator it will be necessary to remove the sound shield if the generator set is so
equipped. The internal air baffle fits closely around the generator making it necessary to move
components out of the way in order to push the baffle on or off the length of the generator (see figure
below).

WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

1. Disconnect the negative (-) cable from the battery to make sure the generator set will not start while
working on it.
2. Remove the DC control box, its four mounts, and mount stiffener ring. Swing the control box down
over the end of the generator so that the air baffle can be pushed off the end of the generator.
3. Disconnect the 3 controller connectors, remove the controller and bracket (4 screws).
4. Disconnect any wiring to components inside the AC control box and remove the box (8 screws).
5. Remove the 4 weld nuts securing the baffle to the top of the generator enclosure and 3 screws
securing the baffle bottom.
6. The hole in the air baffle matches the cross section of the generator and outlet box. Push the air
baffle down the length of the generator until it clears the end.

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No. Description No. Description

1 Air Baffle 5 Bond Strap
2 DC Control Box 6 Bottom of Baffle
3 AC Control Box 7 Foam Seal (both sides)
4 Controller

FIGURE 82. COMPONENTS AFFECTING AIR BAFFLE DISASSEMBLY AND ASSEMBLY.

6.10.2 Removing the Generator Output Box

WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

1. Confirm that the negative (-) cable has been disconnected from the battery to make sure the
generator set cannot start while working on it.
2. If the generator set has a mounted line circuit breaker, disconnect the cables to the circuit breaker.
For reconnections later, make sure each cable is clearly marked to indicate the correct terminal.
3. Disconnect the output box grounding strap.

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4. Disconnect the remote control wiring and conduit. For reconnections later, make sure each wire is
clearly marked to indicate the correct terminal.
5. Disconnect the engine wiring harness connectors.
6. Disconnect all generator control leads (winding taps) from connections in the output box. For
reconnections later, make sure each wire is clearly marked to indicate the correct terminal.
7. Loosen the three output box mounting bolts on each side of the generator and remove the output
box

6.10.3 Removing the Generator

NOTICE
Use the engine barring tool that is available. Using the rotor fan blades to bar the engine can
damage the blades.

1. The rotor must be carried inside the stator when the generator is withdrawn from the engine because
the drive discs alone cannot support the weight of the rotor. Bar the engine until one of the four poles
of the rotor points straight down so that the rotor rests on the face of the pole when the generator is
withdrawn. (Use John Deere flywheel rotating tool JDE81-1.)
2. Attach a lifting eye on each end of the generator using two M10 screws for each lifting eye (see
Figure 80 on page 111).
3. Take up hoist slack and remove the two through bolts securing the generator to the rubber isolation
mounts (Section 5.21 on page 98).
4. Raise the generator end approximately 12 mm (1 inch) and securely block the engine under the
flywheel housing. Lower the generator slightly so that the blocks carry most of the weight.
5. Remove the bolts securing the generator drive discs to the flywheel.
6. Loosen all the bolts securing the generator adapter casting to the flywheel housing. Adjust the hoist
to carry the full weight of the generator, remove the bolts and pull the generator away.

6.10.4 Removing the Rotor

1. Remove the generator adaptor casting on the drive disc end and the end plate on the bearing end.
2. Using a hoist of sufficient capacity, cinch a lifting strap on the drive end of the rotor. Lift the bearing
end of the rotor by hand and push it towards the drive end of the generator until half the width of the
rotor core protrudes from the stator. Release the weight of the rotor and re-cinch the lifting strap
around the middle of the rotor core. Withdraw the rotor until it is free of the stator, guiding it by hand
on both ends to prevent contact with the stator windings
3. Rest the rotor in a cradle, solidly supporting it on two pole faces-not on the drive discs, fan or exciter
rotor.
4. Remove the retaining clip if the rotor shaft bearing is to be removed.

6.11 Generator Reassembly

Reassembling is the reverse of disassembling. Note the following.
1. Apply force to the inner race of the rotor bearing when pressing it onto the shaft, otherwise, it maybe
damaged. Be sure to secure the retaining clip.
2. The drive disc-to-rotor bolts should be torqued to 230 Nm (160 ft-lb). Make sure the bolt washers
face the drive discs with rounded edges toward the discs.

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3. The exciter stator mounting screws should be torqued to 10 Nm (7 ft-lb).

4. Make sure the rubber O-ring is in place in the bearing bore in the generator endplate.
5. The generator end plate mounting bolts should be torqued to 34 Nm (25 ft-lb).
6. The generator-to-adaptor bolts should be torqued to 55 Nm (40 ft-lb).
7. The adaptor-to-engine bolts should be torqued to 48 Nm (35 ft-lb). These bolts should be torqued
before the drive disc is bolted to the flywheel (Step 8).
8. The drive disc-to-flywheel bolts should be torqued to 47 ft-lb (62 Nm). Make sure the bolt washers
face the drive discs with rounded edges toward the discs. If necessary, gently pry the rotor fan up
using a piece of lumber so that the drive discs line up with the locating bore in the face of the
flywheel and slip in.
9. The vibration isolator center bolts should be torqued to 245 Nm (165 ft-lb).
10. Re-install the sound shield if the generator set is so equipped.
a. Push the air baffle on, the length of the generator, to the skid crossmember. The weld nut tabs
along the top edge of the baffle must point as shown in Section 5.21 on page 98. Secure the
baffle bottom to the crossmember with 3 screws.
b. Replace AC control box. Reconnect all wiring to all connectors.
c. Reinstall the controller and bracket.
d. Replace the DC control box, four mounts, and mount stiffener rings on top of the generator
enclosure.
e. Make sure to reconnect the ground bonding strap.
11. Reconnect the generator as required (see Appendix A on page 173).

6.12 Servicing The PMG

The following is applicable if the generator is equipped with a PMG (permanent magnet generator) exciter.

6.12.1 Disassembling the PMG

WARNING
Fire Hazard
Arcing at battery terminals, light switch or other equipment, flame, pilot lights and sparks can
ignite battery gas that can cause severe personal injury or death.
Do not smoke, or switch trouble light ON or OFF near battery. Discharge static electricity from
body before touching batteries by first touching a grounded metal surface.

WARNING
Accidental or Remote Starting
Accidental or remote starting of the generator set can cause severe personal injury or death.
Prevent accidental or remote starting by disconnecting the starting battery cables, negative cable
(–) first, using an insulated wrench and isolating all auxiliary supplies.

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6. Alternator 6-2018

NOTICE
Disconnect battery charger from AC source before disconnecting battery cables. Otherwise,
disconnecting cables can result in voltage spikes damaging to DC control circuits of the set.

1. Disconnect the negative (−) cable from the battery to make sure the set cannot start while working
on it.
2. Remove the PMG cover and disconnect the leads at the connector.
3. Remove the bolts and clamps that secure the PMG stator to the generator frame and carefully pull
away the stator.

NOTICE
The rotor is magnetic and attracts the stator. Hold the stator firmly so that the windings are
not damaged by striking the stator support lugs.

4. The rotor is magnetic and attracts the stator. Hold the stator firmly so that the windings are not
damaged by striking the stator support lugs.

6.12.2 Reassembling the PMG

Reassembling is the reverse of disassembling. Torque the rotor center bolt to 54 Nm (40 ft-lb). The stator
leads must be at 12 o'clock.

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6.12.3 PMG Assembly

No. Description No. Description

1 Dowel Pin 5 Cover
2 PMG Rotor 6 PMG Rotor Through Bolt
3 PMG Stator Clamp 7 PMG Stator
4 Spacer Bolt

FIGURE 83.

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7 Adjusting AC Output Voltage
7.1 Adjusting Voltage
WARNING
Hazardous Voltage
Touching uninsulated live parts inside the generator set and connected equipment can result in
severe personal injury or death.
For your protection, stand on a dry wooden platform or rubber insulating mat, make sure your
clothing and shoes are dry, remove jewelry from your hands, and use tools with insulated
handles. Secure protective covers when completing installation.

1. Before adjusting voltage, make sure that proper fuel, exhaust, raw water, and battery connections
have been made and that the engine has the proper levels of oil and coolant.
2. Disconnect all generator set loads.
3. Connect accurate meters and measure AC voltage and frequency.
4. When reconnecting the alternator for a different output voltage, make sure the line circuit breakers
are suitable for the new output. Replace them if necessary with ones of appropriate rating.

7.2 Voltage Regulator - PMG Excited Generators

7.2.1 Automatic Voltage Regulator (AVR)
Location and Mounting: The figure below illustrates the location and mounting of the AVR used for PMG
excitation. See Appendix A on page 173 for AC Sense and Field connections.

NOTICE
The voltage regulating function of the generator set controller must be disabled. Make sure J16
is connected to P16 in the regulator harness (Appendix A on page 173).

To Replace AVR: When replacing an AVR, make sure the configuration jumpers are on the right
terminals.
• Voltage Trim Jumper - Jumper is required across terminals 1 and 2 to get the full range of voltage
adjustment.
• KW Range Selection Jumper -
◦ For Models MDDCE, MDDCJ and MDDCR use jumper terminals B and C.
◦ For all other models, use jumper terminals A and C.
• Frequency Selection Jumper -
◦ For 60 Hz Models, use jumper 1 and 3.
◦ For 50 Hz Models, use jumper 2 and 3.

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No. Description No. Description

1 Automatic Voltage Regulator 3 Manual Voltage Regulator with Switch and Adjusting
Rheostat
2 Voltage Sensing Transformer 4 Single/Parallel Operation Switch

FIGURE 84. AUTOMATIC AND MANUAL VOLTAGE REGULATORS

7.2.2 Isolation Transformer T30

The figure below illustrates the terminals and schematic of the voltage sensing isolation transformer
windings.
Check for electrical continuity across each winding pair: Input 8-7 and 7-6 and Output 8-7 and 7-6.
Replace a transformer with an open winding See Appendix A on page 173 regarding connections.

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No. Description No. Description

1 Isolation Transformer 3 Output
2 Input 4 Schematic

FIGURE 85. ISOLATION TRANSFORMER T30

7.2.3 Manual Voltage Regulator (Optional)

To test for a faulty manual voltage regulator, disconnect the field and PMG leads from it and connect them
directly to the AVR. If the AVR can regulate voltage properly when the manual regulator is bypassed, but
not when it is in the circuit, the manual regulator is faulty and should be replaced. See Appendix A on
page 173 regarding connections.

7.3 Adjusting Voltage - PMG Excited Generators

7.3.1 Adjusting Voltage Using Voltage Regulator Trimmer
To Adjust Voltage (Section 7.3.3 on page 125):
1. If the generator set has a sound shield enclosure, remove the front access panel below the control
box.

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2. Remove the voltage regulator access cover.

3. Push the SINGLE (PARALLEL) operation switch up to SINGLE. The switch is located below the
voltage regulator access opening.
4. Start the generator set and let voltage and frequency stabilize. Make sure all loads have been
disconnected.
5. Using a small flat-bladed screwdriver, turn the voltage trimmer clockwise to increase voltage or
counterclockwise to decrease voltage.

7.3.2 Adjusting Reactive Droop Compensation

This procedure applies only to generator sets being set up for paralleling.
1. Check for correct droop CT connections and polarity, especially if the generator has been
reconnected (see Appendix A on page 173).
2. Adjust voltage in accordance with the preceding procedure.
3. Push the SINGLE (PARALLEL) operation switch down to PARALLEL. The switch is located below
the voltage regulator access opening.
4. Start the generator set and connect at least 1/2 rated load.
5. Measure voltage at the voltage regulator terminals to which the droop CT leads are connected. You
may expect less than 5 VAC.
6. Multiply the reciprocal of the voltage measured in Step 5 (1 divided by VAC) by 100. This value is the
percentage of full rotation required of the voltage droop trimmer.
Example Calculation: If 1.4 VAC was measured in Step 5, the trim required is: (1 divided by 1.4) time
100 equals 71 percent of full rotation
7. Turn the voltage droop trimmer fully counterclockwise to zero and then clockwise the approximate
percentage of full rotation determined in Step 6.

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7.3.3 Voltage Regulator on PMG-Excited Generators

No. Description No. Description

1 Voltage Droop Trimmer 4 Voltage Droop Trimmer
2 Leads from Droop CT 5 Voltage Trimmer
3 Voltage Trimmer 6 Leads from Droop CT

FIGURE 86. TYPICAL VOLTAGE REGULATOR ON PMG-EXCITED GENERATORS

7.4 Adjusting Voltage - Quad-Winding Excited

Generators
7.4.1 Adjusting Voltage Using Digital Display
1. Start the generator set and let voltage and frequency stabilize for 5 to 10 seconds. Make sure all
loads have been disconnected.
2. Rapidly press START 6 times during the first minute after startup to put the generator set control into
voltage adjust mode. The green status lamp flashes rapidly and the display indicates a status
change from Running to Volt Adj .

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3. To adjust voltage up, press and quickly release START. Voltage increases approximately 0.6 volts
with each press and release.
4. To adjust voltage down, press and hold START for about 1 second. Voltage decreases
approximately 0.6 volts with each press and release.
5. When satisfied with the adjustment, wait about 20 seconds for the display to indicate a status change
from Volt Adj to Running and then press STOP to stop the generator set and save the adjustment.
6. Restart the generator set and check voltage.
7. Recalibrate AC voltage on the digital display as instructed in the Operator Manual.

FIGURE 87. VOLTAGE ADJUSTMENT SCREEN

7.4.2 Adjusting Voltage Using Control Switch

1. Start the generator set and let voltage and frequency stabilize for 5 to 10 seconds. Make sure all
loads have been disconnected.
2. Rapidly press START 6 times during the first minute after start up to put the generator set control
into voltage adjust mode. The amber status lamp begins flashing about once every second to
indicate the change to voltage adjust mode. The green status lamp stays on.
3. To adjust voltage up, press and quickly release START. Voltage increases approximately 0.6 volts
with each press and release.
4. To adjust voltage down, press and hold START for about 1 second. Voltage decreases
approximately 0.6 volts with each press and release.
5. When satisfied with the adjustment, wait about 20 seconds for the amber lamp to stop flashing and
then press STOP to stop the generator set and save the adjustment.
6. Restart the generator set and check voltage.

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8 Troubleshooting
8.1 Overview
NOTICE
Generator Set Servicing
Some generator set service procedures present hazards that can result in severe personal injury
or death.
Only trained and experienced service personnel with knowledge of fuels, electricity, and
machinery hazards should perform generator set service.

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

NOTICE
Many generator set shutdowns can be avoided by performing periodic maintenance on schedule
and by not running the generator set out of fuel. Note that when generator sets and propulsion
engines draw from the same fuel tanks, the fuel pickup tubes are usually arranged so that the
generator sets run out of fuel first. By marking the generator set empty points on the fuel
gauges, it is easier to tell when to stop the generator sets before running them out of fuel.

To troubleshoot the generator set, use the flash control switch status lamp or the digital display fault code
in conjunction with the following list of fault codes (listed in order by fault code number). Perform the step-
by-step corrective actions suggested in this section.

8.2 Troubleshooting with Digital Display

If a fault shutdown occurs the ALARM status lamp on the Digital Display flashes and the LCD screen is
displayed the Fault Number, a description of the fault and the hour the fault occurred in total generator set
running time.
The fault is displayed until it is cleared. Touch any button to clear the fault. The display turns off in 5
minutes after the fault has been cleared.
See the Operator Manual for more information on displaying any of the last five faults.

8.2.1 Fault Code No. 16 and Engine Pre-Alarms

Engine Fault Code No. 16 - If this engine fault occurs, refer to the Engine Fault Code #16 Section later in
this chapter
Engine Pre-Alarms - If an engine pre-alarm condition is displayed, refer to the Troubleshooting Engine
Pre-Alarms Section later in this chapter.

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8.3 Troubleshooting with Status Lamp

If a fault shutdown occurs, the amber status lamp on the control switch repeatedly flashes various sets of
flashes.
• A set of three flashes indicates a service fault.
1. Press Stop once to cause the two-digit shutdown code to flash.
The two-digit code consists of two sets of flashes. The first set is 1 to 7 flashes, which
represents the tens digit of the code number. There is a brief pause, then the second set of 1
to 9 flashes, which represents the units digit of the code number. This is followed by a longer
pause and then repeats the process.
For example, Low Voltage Code No. 13 appears as: flash—pause—flash-flash-flash—long
pause—repeat
2. Pressing Stop again stops the flashing.
• A set of four flashes indicates shutdown due to a failure to start within the time allowed for
cranking.
• A set of five flashes indicates shutdown due to high levels of Carbon Monoxide (CO) in the vessel.
• A set of six flashes indicates shutdown due to low or high engine oil level.
• A set of seven flashes indicates shutdown due to a loss of raw water flow for engine and exhaust
cooling.

NOTICE
The last fault logged flashes even though the condition that caused the shutdown may have been
corrected.

Flashing continues for five minutes and stops. To restore flashing press the control switch to STOP
(Prime) until the lamp comes on (3 to 4 seconds). Then press STOP (Prime) three times to restore
flashing.

8.4 Troubleshooting Generator Set Faults

NOTICE
Generator Set Servicing
Some generator set service procedures present hazards that can result in severe personal injury
or death.
Only trained and experienced service personnel with knowledge of fuels, electricity, and
machinery hazards should perform generator set service.

WARNING
Accidental or Remote Starting
Accidental or remote starting can cause severe personal injury or death.
Before removing a panel or access door, or before working on the generator set, use an
insulated wrench to disconnect the negative (-) cable from the battery to prevent accidental
starting.

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8.4.1 No Code - No Response at Digital Display or Control

Switch
Logic:
Faulty switch, poor or missing connections, dead battery
Diagnosis and Repair:
Refer to Appendix drawings as appropriate.
1. Push the Emergency Stop to remove the emergency stop and/or push DC Circuit Breaker ON if
tripped.
2. Try the local digital display or control switch on the generator set if there is no response at a remote
control switch, and vice versa. If at least one control switch or display works, but not the others, go to
Step 7.
3. If no control switches work, service battery connections as necessary by cleaning and tightening,
recharging or replacing the battery, or replacing damaged battery cables (Section 3.3 on page 28).
4. If there still is no response, disconnect the mate to connector J4 (P4, P33, or P43) in the control box.
Check for battery voltage across pins J4-4 and J4-1 (B+, Display, Start/Stop, and ground). If there is
voltage, go to Step 7. If there is no voltage, go to Step 5.
5. Disconnect connector P2 (grey) from the generator set controller (Section 4.2.3 on page 60) and
check for battery voltage across pin sockets P2-1 and P2-6. If there is voltage, replace the controller.
If there is no voltage, go to Step 6.
6. Test the Emergency Stop Breaker (CB1) (Section 4.7 on page 65) and replace if necessary. If there
still is no voltage, check for and repair faulty wiring and connectors between: P2-1 and CB1-LOAD;
CB1-LINE and B1-BAT; and P2-6 and GND-ENG.
7. Test for and replace a faulty Display or control switch and repair faulty wiring and connectors. See
Appendix A on page 173 for wiring connections.

8.4.2 No Code - Starter Engages and Disengages

Logic:
Low cranking voltage
Diagnosis and Repair:
1. De-energize the PTO clutch, if so equipped.
2. Service battery connections as necessary by cleaning and tightening, recharging or replacing the
battery, or replacing damaged battery cables (Section 3.3 on page 28).
3. Service the starter (Section 5.7 on page 74).

8.4.3 No Code - Starting Batteries Do Not Maintain a Charge

Logic:
Marginal battery, battery connections or charging system
Diagnosis and Repair:
Refer to Appendix drawings as appropriate.
1. Service battery connections as necessary by cleaning and tightening, recharging or replacing the
battery, or replacing damaged battery cables.
2. Check for and disconnect parasitic battery loads.

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3. Service the battery starting alternator.

8.4.4 No Code - No AC Power When Generator Set Is Running

Logic:
A circuit breaker is off, tripped or malfunctioning; or the generator set is not connected properly.
Diagnosis and Repair:
Refer to Appendix drawings as appropriate.
1. Reset, turn on or repair the generator set circuit breaker if off or tripped.
2. Reset, turn on or repair any other circuit breaker in the AC power supply system if off or tripped.
3. If the generator set has a manual voltage regulator, push the manual voltage selector switch to auto.

8.4.5 Code No. 3 - Service Check

Logic:
A fault with a 2-digit fault code number occurred.
Diagnosis and Repair:
Press the STOP switch once. The status lamp flashes the two-digit shutdown code which is one of the
codes in this section. (Does not apply to Digital Display.)

8.4.6 Code No. 4 - Overcrank

Possible Cause:
Cranking time exceeded 20 to 60 seconds, depending on engine temperature.
Diagnosis and Repair:
1. Disconnect the PTO clutch, if so equipped.
2. Check fuel level and refill as necessary. (Note: The generator set fuel pickups are probably higher
than the propulsion engine fuel pickups.)
3. Open any closed fuel supply and return valves.
4. Prime the engine fuel system for at least 30 seconds.
5. Service the battery as necessary by cleaning and tightening connections, recharging or replacing the
battery, or replacing damaged battery cables.
6. Check all fuel fittings for fuel and air leaks, tighten as necessary and reprime.
7. Replace the fuel filters and reprime.
8. If so equipped, check for proper operation of Fuel Pump Relay K7 and fuel pump. Replace or repair
as necessary.
9. Check the engine air filter and remove any blockage.
10. Change engine. Use oil of the proper viscosity for the ambient temperature. High oil viscosity can
slow cranking speed.
11. For all models service the fuel injectors.
12. Check control for any engine fault codes. Troubleshoot any active codes.
13. Have an authorized John Deere Service Representative service the engine.

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8.4.7 Code No. 5 - Warning Shutdown due to CO

Logic:
Dangerous levels of Carbon Monoxide in Vessel.
Diagnosis and Repair:
Get everyone out into fresh air immediately and seek medical attention.

8.4.8 Code No. 6 - Oil Level High or Low

Logic:
Engine oil level is too low or too high.
Diagnosis and Repair: Add or drain oil as necessary, check for leaks.

8.4.9 Code No. 7 - Loss of Raw Water Flow

Logic:
Low raw water pressure in heat exchanger
Diagnosis and Repair:
1. Open the sea cock.
2. Check for and clean a blocked sea water strainer. If above the water line, fill the strainer with water
to assist priming.
3. Check for disconnected, kinked, or leaking hoses and reconnect, reroute, or replace.
4. Check for a worn raw water impeller and replace as necessary.
5. Check the bottom of the hull for any blockage at the through-hull fitting.

8.4.10 Code No. 12 - High AC Voltage

Logic:
After voltage regulation was enabled output voltage jumped to more than 125% of rated for 75
milliseconds or to more than 115% of rated for 3 seconds
Diagnosis and Repair:
1. Does not apply when generator set has PMG excitation.
2. Push the generator set line circuit breaker OFF, start the generator set, and measure output voltage.
If output voltage is normal, the problem is in the circuits external to the generator set. If there is no
voltage, test for grounded or shorted main, field or quadrature windings, and service as necessary.
3. Replace the generator set controller.

8.4.11 Code No. 13 - Low AC Voltage

Logic:
After voltage regulation was enabled output voltage fell to less than 90% of rated for 5 seconds.
Diagnosis and Repair:
1. Does not apply when generator set has PMG excitation.

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2. Push the generator set line circuit breaker to off and disconnect the PTO, if so equipped. If the
generator set now runs and voltage and frequency are normal, reduce the number of electrical and
mechanical (PTO) loads. If there is no voltage, test for grounded or shorted main, field or quadrature
windings, and service as necessary.
3. Replace the generator set controller.

8.4.12 Code No. 14 - High AC Frequency

Logic:
After the starter was engaged frequency jumped to more than 70 Hz for 40 milliseconds or to more than
2% over nominal for 6 seconds.
Diagnosis and Repair:
1. Check for a tripped generator set circuit breaker, reset if necessary, and run with fewer loads. (A
breaker tripping under load can cause generator set frequency to overshoot.)
2. Check all fuel fittings and filters for fuel and air leaks and tighten as necessary. (Air bubbles can
disrupt frequency).
3. Have an authorized John Deere service representative service the engine.

8.4.13 Code No. 15 - Low AC Frequency

Logic:
During normal operation Frequency fell to less than 90% of nominal for more than 8 seconds
Diagnosis and Repair:
1. Push the generator set line circuit breaker off and disconnect the PTO clutch, if so equipped. If the
generator set now runs, reduce the number of electrical and mechanical (PTO) loads, especially
those with high motor starting loads, such as air conditioners.
2. Check the fuel level and fill as necessary.
3. Prime the engine fuel system for at least 30 seconds.
4. Check all fuel fittings for fuel and air leaks and tighten as necessary. (Air bubbles can disrupt
frequency and voltage.)
5. Replace fuel filters and reprime.
6. If so equipped, check for proper operation of Fuel Pump Relay K7 and fuel pump. Repair as
necessary.
7. Check engine air filter and remove any blockage.
8. Service the fuel injectors.
9. Have an authorized John Deere service representative service the engine.

8.4.14 Code No. 16 - Engine Fault

See Section 8.5 on page 136.

8.4.15 Code No. 27 - Loss of AC Voltage Sense

Logic:
The generator set Controller lost VAC sensing during normal voltage regulation when the field was
functioning normally and frequency was at least 40 Hz

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Diagnosis and Repair:

1. Disconnect controller connector J3/P3 and check for loose connections or an open quadrature
winding (P3-4 - P3-5). Service the generator rotor or stator as necessary.
2. Replace the generator set controller.

8.4.16 Code No. 29 - High Battery Voltage

Logic:
During startup the generator set controller sensed that battery system voltage was greater than 19.2 volts
if 12 VDC system, or 32.2 volts if 24 volt system.
Diagnosis and Repair:
1. Check battery bank connections and reconnect if necessary for 12 volts or 24 volts, depending on
generator set model.
2. Select a lower battery booster charge rate (external charging system).

8.4.17 Code No. 32 - Starting Fault

Logic:
The generator set controller could not detect cranking speed [quadrature zero crossings] for 3 seconds.
Diagnosis and Repair:
1. Disconnect the PTO clutch, if so equipped.
2. Have the propulsion engines running while trying to start the generator set. Their charging alternators
may be able to maintain a high enough battery terminal voltage to start the generator set.
3. Service the battery as necessary by cleaning and tightening connections, recharging or replacing the
battery, or replacing damaged battery cables.
4. Change the engine oil to oil of the proper viscosity for the ambient temperature. (High oil viscosity
can slow cranking speed).
5. Check for proper operation of starter relay K5 and J. D. Power Relay K6. Replace if necessary.
6. Service or replace the start solenoid or starter motor assembly.
7. Have an authorized John Deere service representative service the engine.
8. Replace the generator set controller.

8.4.18 Code No. 35 - Control Card Failure - EE

Logic:
During startup the generator set controller detected an EE memory error.
Diagnosis and Repair:
Replace the generator set controller.

8.4.19 Code No. 36 - Unknown Shutdown

Logic:
The generator set controller declared this fault because engine speed fell below 1000 RPM for 0.5
seconds, though not by generator set or engine control action.

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Diagnosis and Repair:

1. Reduce the number of electrical and mechanical (PTO) loads on the generator set.
2. Check fuel level and refill as necessary. (Note: The generator set fuel pickups are probably higher
than the propulsion engine fuel pickups.)
3. Prime the engine fuel system for at least 30 seconds.
4. Check all fuel fittings for fuel and air leaks, tighten as necessary and reprime.
5. Replace the fuel filters and reprime.
6. Check the engine air filter and remove any blockage.
7. Service the fuel injectors.
8. Have an authorized John Deere service representative service the engine.
9. Replace the generator set controller.

8.4.20 Code No. 37 - Invalid Generator Set Configuration

Logic:
The generator set controller is not configured properly for the generator set.
Diagnosis and Repair:
1. Make sure the ends of the two leads marked CONFIG 1 and CONFIG 2 in the control box are not
connected and that they are terminated with insulated connectors.
2. Reconfigure the generator set controller.
3. Replace the generator set controller.

8.4.21 Code No. 43 - Control Card Failure - RAM

Logic:
During startup the generator set Controller detected a RAM memory error
Diagnosis and Repair:
Replace the generator set controller.

8.4.22 Code No. 45 - Speed Sense Lost

Logic:
After start disconnect the generator set controller lost speed sense [quadrature zero crossings] for 0.25
seconds.
Diagnosis and Repair:
1. Disconnect controller connector J3/P3 and check for loose connections or an open quadrature
winding (P3-4 to P3-5). Service generator rotor or stator as necessary.
2. Replace the generator set controller.

8.4.23 Code No. 46 - Generator Set Overload

Logic:
The generator set controller shutdown the generator set because engine load exceeded 135 percent of
generator set rating for 10 seconds.
Diagnosis and Repair:

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Reduce the number of electrical and mechanical (PTO) loads on the generator set.

8.4.24 Code No. 57 - Overprime

Logic:
A local or remote control switch was held in the prime position for more than 5 minutes.
Diagnosis and Repair:
Check for and remove any object that may be holding any control switch (local or remote) in the prime
position.

8.4.25 Code No. 58 - High Exhaust Temperature

Logic:
The temperature of the high exhaust temperature switch exceeds 82° C (180° F) which causes the switch,
which is normally closed, to open. The switch closes again when the temperature decreases to 71° C
(160° F). This fault could be due to a lack of water delivered to the exhaust/water mixer.
Diagnosis and Repair:
1. Check for disconnected, kinked, or leaking water hoses and reconnect, reroute, or replace.
2. Check for and clean a blocked sea water strainer. If strainer is above the water line, fill with water to
assist priming.
3. Inspect the siphon break (if provided) for proper operation.
4. Check for a worn raw water impeller and replace as necessary.

8.4.26 Code No. 59 - Low Coolant Level

Logic:
The engine coolant level fell below the optional coolant level sensor
Diagnosis and Repair:
Add coolant as necessary and repair leaks.

8.4.27 Code No. 61 - External Shutdown

Logic:
The generator set was shut down by a fire suppression system or other external control.
Diagnosis and Repair:
Make all necessary repairs to the generator set and connected equipment. Reset the external control
which shut down the generator set.

8.4.28 Code No. 72 - Lost NIM Communications

Logic:
The generator set controller lost communication with the NIM (Network Interface Module) for 15 seconds.
Diagnosis and Repair:
1. Check for and repair all missing, damaged, or corroded connector pins, sockets, and faulty wiring
connected to NIM board connectors J10 and J11.
2. Replace the NIM board.

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8.5 Engine Fault Code #16

If this fault occurs, press the INFO button (which appears only for this fault) to display the engine FAULT
INFO screen for a description of the engine fault. Find the corresponding fault in the following pages of
this section and perform the step-by-step corrective actions.

FIGURE 88. DISPLAY SCREEN FOR ENGINE FAULT CODE 16.

8.5.1 Code No. SPN: 1, FMI: 0 - Engine Fault, Above Normal

Logic:
Engine controller not in communication with NIM.
Diagnosis and Repair:
1. Check J11-1 to J21-V, J11-2 to J21-U, and J22-3 to J21-F for missing, damaged, or corroded
connector pins, sockets, and faulty wiring. Repair as necessary.
2. Replace the NIM board.
3. Have an authorized John Deere representative service the engine.

8.5.2 Code No. SPN: 97, FMI: 0 - Water In Fuel Indicator, Above
Normal
Logic:
Water is present in the fuel separator.
Diagnosis and Repair:
Drain the water from the fuel separator, see Draining the Fuel Filter in the Maintenance Chapter.

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8.5.3 Code No. SPN: 100, FMI: 1 - Engine Oil Pressure, Below
Normal
Logic:
Engine oil pressure is below 24 to 51 psi (165 to 350 kPa) - depending on engine speed.
Diagnosis and Repair:
1. Check engine oil level and add or drain oil as necessary. Repair any oil leaks.
2. Have an authorized John Deere service representative service the engine.

8.5.4 Code No. SPN: 105, FMI: 0 - Intake Manifold Air

Temperature Signal Out of Range
Logic:
Manifold air temperature signal indicates a temperature greater than 91° C (196° F).
Diagnosis and Repair:
1. Make sure that the wiring harness is connected to the intake manifold air temperature sender.
2. Inspect harness for damage. Repair or replace if necessary.
3. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
4. Have an authorized John Deere service representative service the engine.

8.5.5 Code No. SPN: 110, FMI: 0 - Engine Coolant Temperature,

Above Normal
Logic:
Engine coolant temperature is above 244 °F (118 °C).
Diagnosis and Repair:
1. Check for and clean a blocked sea water strainer. If above the water line, fill the strainer with water
to assist priming.
2. Check engine coolant level and add coolant as necessary. Repair any coolant leaks.
3. Check for disconnected, kinked, or leaking water hoses and reconnect, reroute, or replace.
4. Inspect the siphon break (if provided) for proper operation.
5. Check for a worn raw water impeller and replace as necessary.
6. Check bottom of the hull for blockages at the through-hull fitting.
7. Replace the coolant thermostat, which might not be fully opening.
8. Have an authorized John Deere service representative service the engine.

8.5.6 Code No. SPN: 157, FMI: 3 - Fuel Rail Pressure Signal Out
of Range High
Logic:
Sensor or wiring shorted or open; voltage high.

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Diagnosis and Repair:

1. Make sure that the wiring harness is connected to the fuel rail pressure sender.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.5.7 Code No. SPN: 157, FMI: 4 - Fuel Rail Pressure Signal Out
of Range Low
Logic:
Sensor or wiring shorted or open; voltage low.
Diagnosis and Repair:
1. Make sure that the wiring harness is connected to the Fuel Rail pressure sender.
2. Inspect harness for damage. Repair or replace if necessary.
3. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
4. Have an authorized John Deere service representative service the engine.

8.5.8 Code No. SPN: 174, FMI: 00 - Fuel Temperature Very High
Logic:
Fuel temperature signal corresponds to a fuel temperature greater than 100° C (212° F).
Diagnosis and Repair:
1. Check fuel level. If low, refill and see if code reappears.
2. Check fuel supply lines for restriction or exposure to hot components. Repair or correct.
3. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
4. Have an authorized John Deere service representative service the engine.

8.5.9 Code No. SPN: 190, FMI: 0 - Engine Speed, Above Normal
Logic:
Engine speed exceeded 2070 rpm.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.10 Code No. SPN: 611, FMI: 3 - Injector Shorted to Voltage

Source
Logic:
Injector wiring is shorted to a voltage source.
Diagnosis and Repair:
1. Inspect injector wiring for damage. Repair or replace as necessary.

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2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.5.11 Code No. SPN: 611, FMI: 4 - Injector Shorted to Ground

Logic:
Injector wiring is shorted to ground.
Diagnosis and Repair:
1. Inspect injector wiring for damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.5.12 Code No. SPN: 629, FMI: 13 - Controller #1, Out of Calib.
Logic:
The engine controller requires recalibration
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.13 Code No. SPN: 970, FMI: 31 - Auxiliary Engine Shutdown

Switch
Logic:
An external controller sent a shutdown signal to the engine controller.
Diagnosis and Repair:
Investigate the cause of shutdown, make necessary adjustments and repairs and rest the external
controller.

8.5.14 Code No. SPN: 1076, FMI: 3 - Fuel Injection Pump Valve,
Volt. Out/Range
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.15 Code No. SPN: 1076, FMI: 5 - Fuel Injection Pump Valve,
Cur. Out/Range
Logic:
Fuel injection pump fuel control valve open.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

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8.5.16 Code No. SPN: 1076, FMI: 6 - Fuel Injection Pump Valve,
Cur. Out/Range
Logic:
Fuel injection pump fuel control valve open or grounded.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.17 Code No. SPN: 1076, FMI: 10 - Fuel Injection Pump Valve,
Abnormal Rt/Chg
Logic:
Fuel injection pump fuel control valve circuit resistance.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.18 Code No. SPN: 1076, FMI: 13 - Fuel Injection Pump Valve,
Out of Calib.
Logic:
Fuel injection pump fuel control valve circuit resistance due to connector.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.19 Code No. SPN: 1109, FMI: 31 - Approaching Shutdown

Logic:
Engine controller protection circuit approaching shutdown (30 seconds) - condition not available.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.20 Code No. SPN: 1110, FMI: 31 - Engine Has Shut Down
Logic:
Engine controller protection circuit has shut down - condition not available.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.21 Code No. SPN: 1136, FMI: 0 - ECU Temperature Very High
Logic:
ECU temperature exceeds recommended levels (greater than 135° C (275° F)).
Diagnosis and Repair:
1. Check the ECU for dirt or dust. Clean if necessary.
2. Make sure that the unit is installed correctly and that no exhaust is entering the enclosure.

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3. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
4. Have an authorized John Deere service representative service the engine.

8.5.22 Code No. SPN: 1569, FMI: 31 - Engine Torque Derate

Logic:
A derate condition exists - check coolant temperature, oil pressure, fuel temperature.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.5.23 Code No. SPN:2000, FMI: 06 - ECU Failure, Cur. Out/Range

Logic:
ECU failure
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6 Troubleshooting Engine Pre-Alarms

The PRE-ALARM status lamp starts to flash as certain engine running conditions approach their limits for
engine shutdown. To display information about the pre-alarm condition, press the FAULT button on any
GEN STATUS screen. Then press the ALARM button to display the PRE-ALARM screen. Find the
corresponding fault in the following pages of this section and perform the step-by-step corrective actions.

FIGURE 89. DISPLAY SCREEN FOR PRE-ALARMS.

8.6.1 Code No. SPN: 97, FMI: 16 - Water In Fuel Indicator, Above
Normal
Logic:
Water is present in the fuel separator.
Diagnosis and Repair:
Drain the water from the fuel separator, see Section 3.5.2 on page 33 in the Maintenance Chapter.

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8.6.2 Code No. SPN: 100, FMI: 3 - Engine Oil Pressure,Voltage

Out of Range
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.3 Code No. SPN: 100, FMI: 4 - Engine Oil Pressure, Volt.
Out/Range
Logic:
Engine oil pressure sensor or wiring open or grounded.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.4 Code No. SPN: 100, FMI:18 - Engine Oil Pressure, Below
Normal
Logic:
Engine oil pressure is below 24 to 51 psi (165 to 350 kPa) - depending on engine speed.
Diagnosis and Repair:
1. Check engine oil level and add or drain oil as necessary. Repair any oil leaks.
2. Have an authorized John Deere service representative service the engine.

8.6.5 Code No. SPN: 105, FMI: 3 - Intake Manifold Temperature,

Volt. Out/Range
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
Check engine oil level and add or drain oil as necessary. Repair any oil leaks.

8.6.6 Code No. SPN: 105, FMI: 4 - Intake Manifold Air

Temperature Signal Out of Range
Logic:
Signal voltage from the manifold air temperature sensor is outside the possible range.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the crankshaft position sensor is connected to the wiring harness.
3. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
4. Have an authorized John Deere service representative service the engine.

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8.6.7 Code No. SPN: 105, FMI: 15 - Intake Manifold Air

Temperature High
Logic:
Manifold air temperature signal indicates temperature greater than 88° C (190° F).
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Check air intake system for excess restriction. Repair as necessary.
3. Make sure that no exhaust gases are recirculating into the intake. Repair as necessary.
4. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
5. Have an authorized John Deere service representative service the engine.

8.6.8 Code No. SPN: 105, FMI: 16 - Intake Manifold Temperature,

Above Normal
Logic:
Intake manifold temperature above 302 °F (150 °C)
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.9 Code No. SPN: 110, FMI: 3 - Engine Coolant Temperature,

Volt. Out/Range
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.10 Code No. SPN: 110, FMI: 4 - Engine Coolant Temperature,

Volt. Out/Range
Logic:
Sensor or wiring shorted to ground.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.11 Code No. SPN: 110, FMI: 15 - Engine Coolant Temperature,

Above Normal
Logic:
Engine coolant temperature is above 226 °F (108 °C).

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Diagnosis and Repair:

1. Check for and clean a blocked sea water strainer. If above the water line, fill the strainer with water
to assist priming.
2. Check engine coolant level and add coolant as necessary. Repair any coolant leaks.
3. Check for disconnected, kinked, or leaking water hoses and reconnect, reroute, or replace.
4. Inspect the siphon break (if provided) for proper operation (Section 3.6.4 on page 40).
5. Check for a worn raw water impeller and replace as necessary.
6. Check bottom of the hull for blockages at the through-hull fitting.

8.6.12 Code No. SPN: 110, FMI: 16 - Engine Coolant Temperature,

Above Normal
Logic:
Engine coolant temperature is above 235 °F (113 °C).
Diagnosis and Repair:
1. Check for and clean a blocked sea water strainer. If above the water line, fill the strainer with water
to assist priming.
2. Check engine coolant level and add coolant as necessary. Repair any coolant leaks.
3. Check for disconnected, kinked, or leaking water hoses and reconnect, reroute, or replace.
4. Inspect the siphon break (if provided) for proper operation (Section 3.6.4 on page 40).
5. Check for a worn raw water impeller and replace as necessary.
6. Check bottom of the hull for blockages at the through-hull fitting.

8.6.13 Code No. SPN: 157, FMI: 10 - Fuel Rail Pressure Loss
Logic:
Fuel rail pressure signal indicates a rapid loss of rail pressure.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.14 Code No. SPN: 157, FMI: 17 - Fuel Rail Pressure Not
Developed
Logic:
Less than 1000 kPa rail pressure detected after 3 seconds of cranking.
Diagnosis and Repair:
1. Check fuel level and refill as necessary.

NOTICE
The generator set fuel pickups are probably higher than the propulsion engine fuel pickups.

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2. Open any closed fuel supply and return valves.

3. Prime engine fuel system for at least 30 seconds.
4. Replace the fuel filters and re-prime.
5. If so equipped, check for proper operation of fuel pump relay K7 and fuel pump. Replace or repair as
necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere service representative service the engine.

8.6.15 Code No. SPN: 158, FMI: 17 - Battery Potential, Below

Normal
Logic:
ECU cannot power down.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.16 Code No. SPN: 174, FMI: 3 - Fuel Temperature, Volt.

Out/Range
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.17 Code No. SPN: 174, FMI: 4 - Fuel Temperature, Volt.

Out/Range
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.18 Code No. SPN: 174, FMI: 16 - Fuel Temperature, Above

Normal
Logic:
Return fuel temperature is above 248 °F (120 °C).
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.19 Code No. SPN: 189, FMI: 00 - Engine Speed Derate

Logic:
Another code has triggered a cap on maximum engine speed.

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Diagnosis and Repair:

1. Check fault history for other faults. Resolve faults if necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.20 Code No. SPN: 620, FMI: 3 - 5 Volts DC Supply, Volt.

Out/Range
Logic:
5 V supply shorted to battery voltage.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.21 Code No. SPN: 620, FMI: 4 - 5 Volts DC Supply, Volt.

Out/Range
Logic:
5 V supply shorted to ground.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.22 Code No. SPN: 636, FMI: 2 - Camshaft Position Signal

Invalid
Logic:
Noise or incorrect signal registered from camshaft position sensor.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the camshaft position sensor is connected to the wiring harness.
3. Remove sensor and inspect for damage, including possible damage to the tip. Replace if necessary.
4. Using a multimeter, measure the resistance across the two leads on the camshaft position sensor.
The resistance should be between 2500 and 3500 ohms. If it is not, replace the sensor.
5. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
camshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace the harness as necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere service representative service the engine.

8.6.23 Code No. SPN: 636, FMI: 5 - Camshaft Position Circuit

Resistance High
Logic:
Higher resistance than expected in the camshaft position circuit.

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Diagnosis and Repair:

1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the camshaft position sensor is connected to the wiring harness.
3. Remove sensor and inspect for damage, including possible damage to the tip. Replace if necessary.
4. Disconnect the harness from the ECU. Using a multimeter, measure the resistance across the two
leads on the camshaft position sensor. The resistance should be between 2500 and 3500 ohms. If it
is not, replace the sensor.
5. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
camshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace harness if necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere service representative service the engine.

8.6.24 Code No. SPN: 636, FMI: 6 - Camshaft Position Circuit

Resistance Low
Logic:
Lower resistance than expected in the camshaft position circuit.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the camshaft position sensor is connected to the wiring harness.
3. Remove sensor and inspect for damage, including possible damage to the tip. Replace if necessary.
4. Using a multimeter, measure the resistance across the two leads on the camshaft position sensor.
The resistance should be between 2500 and 3500 ohms. If it is not, replace the sensor.
5. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
camshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace harness if necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere service representative service the engine.

8.6.25 Code No. SPN: 636, FMI: 8 - Camshaft Position Signal

Missing
Logic:
No camshaft position signal detected by the ECU.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the camshaft position sensor is connected to the wiring harness.
3. Remove sensor and inspect for damage, including possible damage to the tip. Replace if necessary.
4. Using a multimeter, measure the resistance across the two leads on the camshaft position sensor.
The resistance should be between 2500 and 3500 ohms. If it is not, replace the sensor.

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5. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
camshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace harness if necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere service representative service the engine.

8.6.26 Code No. SPN: 636, FMI: 10 - Camshaft Position Signal

Rate of Change Abnormal
Logic:
Incorrect signal, noise, or other signal fault occurred on the camshaft position signal.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the camshaft position sensor is connected to the wiring harness.
3. Remove sensor and inspect for damage, including possible damage to the tip. Replace if necessary.
4. Using a multimeter, measure the resistance across the two leads on the camshaft position sensor.
The resistance should be between 2500 and 3500 ohms. If it is not, replace the sensor.
5. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
camshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace harness if necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere representative service the engine.

8.6.27 Code No. SPN: 637, FMI: 2 - Timing (Crank) Sensor, Data
Erratic
Logic:
Excessive signal noise.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.28 Code No. SPN: 637, FMI: 5 - Crankshaft Position Circuit

Resistance High
Logic:
Higher resistance than expected in the crankshaft position circuit.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the crankshaft position sensor is connected to the wiring harness.
3. Remove sensor and inspect for damage, including possible damage to the tip. Replace if necessary.
4. Using a multimeter, measure the resistance across the two leads on the crankshaft position sensor.
The resistance should be between 2500 and 3500 ohms. If it is not, replace the sensor.

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5. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
crankshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace harness if necessary.
6. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
7. Have an authorized John Deere service representative service the engine.

8.6.29 Code No. SPN: 637, FMI: 7 - Crankshaft and Camshaft

Signals Out of Sync
Logic:
Signals from crankshaft and camshaft position sensors do not show the correct relative positions.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the crankshaft position sensor is connected to the wiring harness.
3. Inspect for evidence of moisture on or in the connector. If necessary, dry the connectors with
Cummins electronic cleaner, part number 3824510.
4. Remove sensors and inspect for damage, including possible damage to the tip. Replace if
necessary.
5. Using a multimeter, measure the resistance across the two leads on the crankshaft and camshaft
position sensors. The resistances should be between 2500 and 3500 ohms. If they are not, replace
the sensor.
6. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
crankshaft position leads on the wiring harness. Repeat for camshaft position leads. Resistances
should be greater than 1000 ohms. Repair or replace harness if necessary.
7. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
8. Have an authorized John Deere service representative service the engine.

8.6.30 Code No. SPN: 637, FMI: 8 - No Crankshaft Position Signal

Logic:
No crankshaft position signal at the ECU.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the crankshaft position sensor is connected to the wiring harness.
3. Using a multimeter, measure the resistance across the two leads on the crankshaft position sensor.
The resistance should be between 2500 and 3500 ohms; if it is not, replace the sensor.
4. Disconnect the harness from the ECU. Using a multimeter, measure the resistance between the two
crankshaft position leads on the wiring harness. Resistance should be greater than 1000 ohms.
Repair or replace harness as necessary.
5. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
6. Have an authorized John Deere service representative service the engine.

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8.6.31 Code No. SPN: 637, FMI: 10 - Timing (Crank) Sensor,

Abnormal Rt/Chg.
Logic:
Improper signal pattern.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.32 Code No. SPN: 640, FMI: 31 - External Derate Commanded

Logic:
An external controller has commanded the engine to derate.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.33 Code No. SPN: 651, FMI: 2 - Injector #1 Part Number

Invalid
Logic:
Injector #1 returns the wrong part number to the ECU.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.34 Code No. SPN: 651, FMI: 5 - Injector #1 High Resistance

Logic:
Injector #1 circuit resistance is higher than expected.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.35 Code No. SPN: 651, FMI: 6 - Injector #1 Circuit Resistance

Low
Logic:
Injector #1 circuit has lower resistance than expected.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.

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3. Have an authorized John Deere service representative service the engine.

8.6.36 Code No. SPN: 651, FMI: 7 - Injector #1 Not Responding

Logic:
No fuel rail pressure change during injector #1 cycle.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.37 Code No. SPN: 651, FMI: 13 - Calibration Fault: Injector #1

Logic:
ECU calibrated for incorrect injector QR code for injector #1.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.38 Code No. SPN: 652, FMI: 2 - Injector #2 Part Number

Invalid
Logic:
Injector #2 returns the wrong part number to the ECU.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.39 Code No. SPN: 652, FMI: 5 - Injector #2 High Resistance

Logic:
Injector #2 circuit resistance is higher than expected.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.40 Code No. SPN: 652, FMI: 6 - Injector #2 Circuit Resistance

Low
Logic:
Injector #2 circuit has lower resistance than expected.
Diagnosis and Repair:
1. Inspect wiring for wear or damage, repair or replace as necessary.

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8. Troubleshooting 6-2018

2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.41 Code No. SPN: 652, FMI: 7 - Injector #2 Not Responding

Logic:
No fuel rail pressure change during injector #2 cycle.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.42 Code No. SPN: 652, FMI: 13 - Calibration Fault: Injector #2

Logic:
ECU calibrated for incorrect injector QR code for injector #2.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.43 Code No. SPN: 653, FMI: 2 - Injector #3 Part Number

Invalid
Logic:
Injector #3 returns the wrong part number to the ECU.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.44 Code No. SPN: 653, FMI: 5 - Injector #3 High Resistance

Logic:
Injector #3 circuit resistance is higher than expected.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.45 Code No. SPN: 653, FMI: 6 - Injector #3 Circuit Resistance

Low
Logic:
Injector #3 circuit has lower resistance than expected.

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Diagnosis and Repair:

1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.46 Code No. SPN: 653, FMI: 7 - Injector #3 Not Responding

Logic:
No fuel rail pressure change during injector #3 cycle.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.47 Code No. SPN: 653, FMI: 13 - Calibration Fault: Injector #3

Logic:
ECU calibrated for incorrect injector QR code for injector #3.
Diagnosis and Repair:
1. Have an authorized John Deere service representative service the engine.

8.6.48 Code No. SPN: 654, FMI: 2 - Injector #4 Part Number

Invalid
Logic:
Injector #4 returns the wrong part number to the ECU.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.49 Code No. SPN: 654, FMI: 5 - Injector #4 High Resistance

Logic:
Injector #4 circuit resistance is higher than expected.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.50 Code No. SPN: 654, FMI: 6 - Injector #4 Circuit Resistance

Low
Logic:
Injector #4 circuit has lower resistance than expected.

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Diagnosis and Repair:

1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.51 Code No. SPN: 654, FMI: 7 - Injector #4 Not Responding

Logic:
No fuel rail pressure change during injector #4 cycle.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.52 Code No. SPN: 654, FMI: 13 - Calibration Fault: Injector #4

Logic:
ECU calibrated for incorrect injector QR code for injector #4.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.53 Code No. SPN: 971, FMI: 31 - Engine Derate Switch

Logic:
An external derate input has been activated.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.54 Code No. SPN: 1076, FMI: 0 - Fuel Injection Pump Valve,
Above Normal
Logic:
Closure too long.
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.55 Code No. SPN: 1076, FMI: 1 - Fuel Injection Pump Valve,
Above Normal
Logic:
Closure too short.
Diagnosis and Repair:

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Have an authorized John Deere service representative service the engine.

8.6.56 Code No. SPN: 1076, FMI: 7 - Fuel Injection Pump Valve,
Above Normal
Logic:
ECU failed to detect closure
Diagnosis and Repair:
Have an authorized John Deere service representative service the engine.

8.6.57 Code No. SPN: 1347, FMI: 3 - Suction Control Valve Signal
Out of Range High
Logic:
Short or open circuit; high current detected in suction control return wire.
Diagnosis and Repair:
1. Inspect injector wiring for damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.58 Code No. SPN: 1347, FMI: 5 - Suction Control Valve Signal
High Resistance
Logic:
Actual pump current does not match requested pump current.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.59 Code No. SPN: 1347, FMI: 7 - Fuel Rail Pressure Does Not
Match Commanded
Logic:
Measured fuel rail pressure is more than 5 MPa (725 psi) different than commanded.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

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8.6.60 Code No. SPN: 1349, FMI: 2 - Detected Fuel Rail Pressures
Do Not Match
Logic:
Fuel rail pressure signals differ by greater than 15 MPa (2176 psi).
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Have an authorized John Deere service representative service the engine.

8.6.61 Code No. SPN: 1349, FMI: 3 - Secondary Fuel Rail

Pressure Signal Out of Range High
Logic:
Secondary fuel pressure signal voltage is above and outside the possible operating range.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
3. Have an authorized John Deere service representative service the engine.

8.6.62 Code No. SPN: 1349, FMI: 4 - Secondary Fuel Rail

Pressure Signal Out of Range Low
Logic:
Secondary fuel pressure signal voltage is below and outside the possible operating range.
Diagnosis and Repair:
1. Inspect wiring for wear or damage. Repair or replace as necessary.
2. Make sure that the secondary fuel rail pressure sensor is connected to the wiring harness.
3. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
4. Have an authorized John Deere service representative service the engine.

8.6.63 Code No. SPN: 1136, FMI: 16 - ECU Temperature High

Logic:
ECU temperature exceeds recommended levels (greater than 125° C (257° F)).
Diagnosis and Repair:
1. Inspect the ECU for dirt or dust. Clean if necessary.
2. Make sure that the unit is installed correctly, and that exhaust gases are not entering the enclosure.
3. If John Deere ADVISOR software and harness are available, follow the in-tool troubleshooting.
4. Have an authorized John Deere service representative service the engine.

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8.6.64 Code No. SPN: 2000, FMI: 13 - Incorrect ECU

Logic:
Engine Control is incorrect for application.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.65 Code No. SPN: 523792, FMI: 4 - EPGDS LTC Pump Signal
Out of Range Low
Logic:
Sensor or wiring shorted or open.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

8.6.66 Code No. SPN: 524099, FMI: 11 - EPGDS LTC Pump

Blockage
Logic:
The EPGDS LTC pump is blocked.
Diagnosis and Repair:
1. If John Deere Service ADVISOR software and harness are available, follow the in-tool
troubleshooting.
2. Have an authorized John Deere service representative service the engine.

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9 Specifications
9.1 MDDCA, MDDCB, MDDCC, MDDCD, MDDCL,
MDDCM, MDDCN, and MDDCP Specifications Table
TABLE 6. GENERATOR SET SPECIFICATIONS

DESCRIPTION MDDCA, MDDCL MDDCB, MDDCM MDDCC, MDDCN MDDCD, MDDCP

Single Bearing, 4- Single Bearing, 4- Single Bearing, 4- Single Bearing, 4-
Alternator Pole Rotating Field, Pole Rotating Field, Pole Rotating Field, Pole Rotating Field,
Brushless Brushless Brushless Brushless
Installation Drawing 0500-3799 0500-3799 0500-3799 0500-3800
John Deere 4-Stroke John Deere 4-Stroke John Deere 4-Stroke John Deere 4-Stroke
Engine Cycle, turbocharged, Cycle, turbocharged, Cycle, turbocharged, Cycle, turbocharged,
water cooled diesel water cooled diesel water cooled diesel water cooled diesel
Model 4045TFM 4045TFM 4045TFM 6068TFM
Output Ratings
(Engine Power)
60 Hz 107 hp/80 kW 107 hp/80 kW 107 hp/80 kW 162 hp/121 kW
50 Hz 82 hp/61 kW 82 hp/61 kW 82 hp/61 kW 131 hp/98 kW
Rated RPM
60 Hz 1800 1800 1800 1800
50 Hz N/A N/A N/A N/A
Number of Cylinders 4 4 4 6
Bore 106.5 mm (4.19 in) 106.5 mm (4.19 in) 106.5 mm (4.19 in) 106.5 mm (4.19 in)
Stroke 127 mm (5 in) 127 mm (5 in) 127 mm (5 in) 127 mm (5 in)
Displacement 4.5 L (275 in3) 4.5 L (275 in3) 4.5 L (275 in3) 6.8 L (415 in3)
FUEL:
Bio-Diesel
Spec C and up Spec C and up Spec C and up Spec C and up
Compatibility
Consumption - 60
Hz
Full Load 12.9 L/hr (3.4 gal/hr) 16.7 L/hr (4.4 gal/hr) 19.7 L/hr (5.2 gal/hr) 24.2 L/hr (6.4 gal/hr)
Half Load 7.2 L/hr (1.9 gal/hr) 9.1 L/hr (2.4 gal/hr) 10.6 L/hr (2.8 gal/hr) 13.2 L/hr (3.5 gal/hr)
Consumption - 50
Hz
Full Load N/A N/A N/A N/A
Half Load N/A N/A N/A N/A

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DESCRIPTION MDDCA, MDDCL MDDCB, MDDCM MDDCC, MDDCN MDDCD, MDDCP

Max Fuel Pump Lift
Minimum Fuel Inlet
- 3.5 psi - 3.5 psi - 3.5 psi - 3.5 psi
Pressure
Minimum Fuel Inlet
Pressure with - 8.5 psi - 8.5 psi - 8.5 psi - 8.5 psi
Auxiliary Pump
Maximum Fuel Height
above Injection Pump 3 m (10 ft) 3 m (10 ft) 3 m (10 ft) 3 m (10 ft)
Supply Pressure
Recommended Fuel
Line Size
Maximum Fuel Return
3 psi 3 psi 3 psi 3 psi
Pressure (Restriction)
LUBRICATION:
Engine Oil Capacity 12.6 L (13.3 qt) 12.6 L (13.3 qt) 12.6 L (13.3 qt) 19.4 L (20.5 qt)
Maximum Angularity
any Direction
Continuous 30° 30° 30° 30°
Intermittent 30° 30° 30° 30°
COOLING:
Coolant Capacity 14 L (15 qt) 14 L (15 qt) 14 L (15 qt) 30 L (32 qt)
Coolant Flow Rate
125 L/min (33
60 Hz 94 L/min (25 gal/min) 94 L/min (25 gal/min) 94 L/min (25 gal/min)
gal/min)
50 Hz N/A N/A N/A N/A
Raw Water Flow
Rate
60 Hz 83 L/min (22 gal/min) 83 L/min (22 gal/min) 83 L/min (22 gal/min) 83 L/min (22 gal/min)
50 Hz N/A N/A N/A N/A
Minimum Raw Water
- 4 psi - 4 psi - 4 psi - 4 psi
Inlet Pressure
Maximum Pressure
Drop across Keel
4 psi 4 psi 4 psi 4 psi
Cooler Outlet and
Inlet Connection
Heat Rejection to
Coolant
888 Kcal/min (3523 888 Kcal/min (3523 888 Kcal/min (3523 1477 Kcal/min (5863
60 Hz
BTU/min) BTU/min) BTU/min) BTU/min)
50 Hz N/A N/A N/A N/A

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DESCRIPTION MDDCA, MDDCL MDDCB, MDDCM MDDCC, MDDCN MDDCD, MDDCP

Thermostat Opening
82 °C (180 °F) 82 °C (180 °F) 82 °C (180 °F) 82 °C (180 °F)
Temperature
Thermostat Fully 95 °C (203 °F)
95 °C (203 °F) 95 °C (203 °F) 95 °C (203 °F)
Open Temperature
Recommended
70 kPA (10 psi) 70 kPA (10 psi) 70 kPA (10 psi) 70 kPA (10 psi)
Pressure Cap
GENERATOR SET
AIR FLOW:
5.2 m3/min (184 5.2 m3/min (184 5.2 m3/min (184 10.7 m3/min (378
Combustion Air Flow
ft3/min) ft3/min) ft3/min) ft3/min)
Heat Rejection to
Ambient
243 Kcal/min (965 281 Kcal/min (1116 306 Kcal/min (1216 416 Kcal/min (1651
60 Hz
Btu/min) Btu/min) Btu/min) Btu/min)
50 Hz N/A N/A N/A N/A
EXHAUST:
Maximum Exhaust
2.2 in Hg 2.2 in Hg 2.2 in Hg 2.2 in Hg
Back Pressure
Dry Exhaust Gas 13.1 m3/min (463 13.1 m3/min (463 13.1 m3/min (463 24 m3/min (848
Flow ft3/min) ft3/min) ft3/min) ft3/min)
Dry Exhaust
476 °C (889 °F) 476 °C (889 °F) 476 °C (889 °F) 396 °C (745 °F)
Temperature
BATTERIES:
Nominal Battery
12/24 VDC 12/24 VDC 12/24 VDC 12/24 VDC
Voltage
Minimum CCA Rating
- SAE @ 0 °C (32 °F) 640 Amps 640 Amps 640 Amps 800 Amps
12 VDC
Minimum CCA Rating
- SAE @ 0 °C (32 °F) 570 Amps 570 Amps 570 Amps 570 Amps
24 VDC
12 Volt Net Battery
Charging Output
Negative Ground (60
60 Amps 60 Amps 60 Amps 60 Amps
Hz)
Isolated Ground (60
37 Amps 70 Amps 70 Amps 70 Amps
Hz)
Negative Ground (50
N/A N/A N/A N/A
Hz)
Isolated Ground (50
N/A N/A N/A N/A
Hz)

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DESCRIPTION MDDCA, MDDCL MDDCB, MDDCM MDDCC, MDDCN MDDCD, MDDCP

24 Volt Net Battery
Charging Output
Negative Ground (60
21 Amps 40 Amps 40 Amps 40 Amps
Hz)
Isolated Ground (60
26 Amps 45 Amps 45 Amps 45 Amps
Hz)
Negative Ground (50
N/A N/A N/A N/A
Hz)
Isolated Ground (50
N/A N/A N/A N/A
Hz)
Starter Rolling
Current
12V 780 Amps 780 Amps 780 Amps 920 Amps
24V 600 Amps 600 Amps 600 Amps 600 Amps
Maximum Starting
Current Resistance
12V 0.0012 ohms 0.0012 ohms 0.0012 ohms 0.0012 ohms
24V 0.002 ohms 0.002 ohms 0.002 ohms 0.002 ohms
SIZE, WEIGHT,
NOISE:
Weight without
Sound Shield:
Dry Weight 972 kg (2143 lb) 1067 kg (2352 lb) 1067 kg (2352 lb) 1320 kg (2910 lb)
Weight with Sound
Shield:
Dry Weight 1072 kg (2420 lb) 1167 kg (2572 lb) 1167 kg (2572 lb) 1433 kg (3161 lb)
Sound Level with
Sound Shield @ 1 72 dB(A) @ 60 Hz 72 dB(A) @ 60 Hz 72 dB(A) @ 60 Hz 72 dB(A) @ 60 Hz
meter

9.2 MDDCE, MDDCF, MDDCG and MDDCR

Specifications Table
TABLE 7. GENERATOR SET SPECIFICATIONS

DESCRIPTION MDDCE, MDDCR MDDCF MDDCG

Single Bearing, 4- Pole Single Bearing, 4- Pole Single Bearing, 4- Pole
Alternator
Rotating Field, Brushless Rotating Field, Brushless Rotating Field, Brushless
Installation Drawing 0500-3800 0500-3799 0500-3799

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DESCRIPTION MDDCE, MDDCR MDDCF MDDCG

John Deere 4-Stroke Cycle, John Deere 4-Stroke Cycle, John Deere 4-Stroke Cycle,
Engine turbocharged, water cooled turbocharged, water cooled turbocharged, water cooled
diesel diesel diesel
Model 6068TFM 4045TFM 4045TFM
Output Ratings (Engine
Power)
60 Hz 162 hp/121 kW 107 hp/80 kW 107 hp/80 kW
50 Hz 131 hp/98 kW 82 hp/61 kW 82 hp/61 kW
Rated RPM
60 Hz 1800 N/A N/A
50 Hz N/A 1500 1500
Number of Cylinders 6 4 4
Bore 106.5 mm (4.19 in) 106.5 mm (4.19 in) 106.5 mm (4.19 in)
Stroke 127 mm (5 in) 127 mm (5 in) 127 mm (5 in)
Displacement 6.8 L (415 in3) 4.5 L (275 in3) 4.5 L (275 in3)
FUEL:
Bio-Diesel Compatibility Spec C and up Spec C and up Spec C and up
Consumption - 60 Hz
Full Load 29.5 L/hr (7.8 gal/hr) N/A N/A
Half Load 15.5 L/hr (4.1 gal/hr) N/A N/A
Consumption - 50 Hz
Full Load N/A 11.4 L/hr (3 gal/hr) 14 L/hr (3.7 gal/hr)
Half Load N/A 6.4 L/hr (1.7 gal/hr) 7.6 L/hr (2 gal/hr)
Max Fuel Pump Lift
Minimum Fuel Inlet
- 3.5 psi - 3.5 psi - 3.5 psi
Pressure
Minimum Fuel Inlet
Pressure with Auxiliary - 8.5 psi - 8.5 psi - 8.5 psi
Pump
Maximum Fuel Height
above Injection Pump 3 m (10 ft) 3 m (10 ft) 3 m (10 ft)
Supply Pressure
Recommended Fuel Line
Size
Maximum Fuel Return
3 psi 3 psi 3 psi
Pressure (Restriction)
LUBRICATION:
Engine Oil Capacity 19.4 L (20.5 qt) 12.6 L (13.3 qt) 12.6 L (13.3 qt)

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9. Specifications 6-2018

DESCRIPTION MDDCE, MDDCR MDDCF MDDCG

Maximum Angularity any
Direction
Continuous 30° 30° 30°
Intermittent 30° 30° 30°
COOLING:
Coolant Capacity 30 L (32 qt) 14 L (15 qt) 14 L (15 qt)
Coolant Flow Rate
60 Hz 125 L/min (33 gal/min) N/A N/A
50 Hz N/A 53 L/min (14 gal/min) 53 L/min (14 gal/min)
Raw Water Flow Rate
60 Hz 83 L/min (22 gal/min) N/A N/A
50 Hz N/A 68 L/min (18 gal/min) 68 L/min (18 gal/min)
Minimum Raw Water Inlet
- 4 psi - 4 psi - 4 psi
Pressure
Maximum Pressure Drop
across Keel Cooler Outlet 4 psi 3 psi 3 psi
and Inlet Connection
Heat Rejection to Coolant
1477 Kcal/min (5863
60 Hz N/A N/A
BTU/min)
676 Kcal/min (2681 676 Kcal/min (2681
50 Hz N/A
BTU/min) BTU/min)
Thermostat Opening
82 °C (180 °F) 82 °C (180 °F) 82 °C (180 °F)
Temperature
Thermostat Fully Open 95 °C (203 °F)
95 °C (203 °F) 95 °C (203 °F)
Temperature
Recommended Pressure
70 kPA (10 psi) 70 kPA (10 psi) 70 kPA (10 psi)
Cap
GENERATOR SET AIR
FLOW:
Combustion Air Flow 10.7 m3/min (378 ft3/min) 3.5 m3/min (124 ft3/min) 3.5 m3/min (124 ft3/min)
Heat Rejection to Ambient
464 Kcal/min (1842
60 Hz N/A N/A
Btu/min)
50 Hz N/A 203 Kcal/min (805 Btu/min) 228 Kcal/min (906 Btu/min)
EXHAUST:
Maximum Exhaust Back
2.2 in Hg 2.2 in Hg 2.2 in Hg
Pressure
Dry Exhaust Gas Flow 24 m3/min (848 ft3/min) 8.5 m3/min (300 ft3/min) 8.5 m3/min (300 ft3/min)

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DESCRIPTION MDDCE, MDDCR MDDCF MDDCG

Dry Exhaust Temperature 396 °C (745 °F) 455 °C (851 °F) 455 °C (851 °F)
BATTERIES:
Nominal Battery Voltage 12/24 VDC 12/24 VDC 12/24 VDC
Minimum CCA Rating - SAE
800 Amps 640 Amps 640 Amps
@ 0 °C (32 °F) 12 VDC
Minimum CCA Rating - SAE
570 Amps 570 Amps 570 Amps
@ 0 °C (32 °F) 24 VDC
12 Volt Net Battery
Charging Output
Negative Ground (60 Hz) 60 Amps N/A N/A
Isolated Ground (60 Hz) 70 Amps N/A N/A
Negative Ground (50 Hz) N/A 60 Amps 60 Amps
Isolated Ground (50 Hz) N/A 70 Amps 70 Amps
24 Volt Net Battery
Charging Output
Negative Ground (60 Hz) 40 Amps N/A N/A
Isolated Ground (60 Hz) 45 Amps N/A N/A
Negative Ground (50 Hz) N/A 40 Amps 40 Amps
Isolated Ground (50 Hz) N/A 45 Amps 45 Amps
Starter Rolling Current
12V 920 Amps 780 Amps 780 Amps
24V 600 Amps 600 Amps 600 Amps
Maximum Starting Current
Resistance
12V 0.0012 ohms 0.0012 ohms 0.0012 ohms
24V 0.002 ohms 0.002 ohms 0.002 ohms
SIZE, WEIGHT, NOISE:
Weight without Sound
Shield:
Dry Weight 1320 kg (2910 lb) 998 kg (2200 lb) 1067 kg (2352 lb)
Weight with Sound
Shield:
Dry Weight 1433 kg (3161 lb) 1098 kg (2420 lb) 1167 kg (2572 lb)
Sound Level with Sound
72 dB(A) @ 60 Hz 72 dB(A) @ 50 Hz 72 dB(A) @ 50 Hz
Shield @ 1 meter

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9. Specifications 6-2018

9.3 MDDCH, MDDCJ, and MDDCK Specifications Table

TABLE 8. GENERATOR SET SPECIFICATIONS

DESCRIPTION MDDCH MDDCJ MDDCK

Single Bearing, 4- Pole Single Bearing, 4- Pole Single Bearing, 4- Pole
Alternator
Rotating Field, Brushless Rotating Field, Brushless Rotating Field, Brushless
Installation Drawing 0500-3800 0500-3800 0500-3799
John Deere 4-Stroke Cycle, John Deere 4-Stroke Cycle, John Deere 4-Stroke Cycle,
Engine turbocharged, water cooled turbocharged, water cooled turbocharged, water cooled
diesel diesel diesel
Model 6068TFM 6068TFM 4045TFM
Output Ratings (Engine
Power)
60 Hz 162 hp/121 kW 162 hp/121 kW 107 hp/80 kW
50 Hz 131 hp/98 kW 131 hp/98 kW 82 hp/61 kW
Rated RPM
60 Hz N/A N/A N/A
50 Hz 1500 1500 1500
Number of Cylinders 6 6 4
Bore 106.5 mm (4.19 in) 106.5 mm (4.19 in) 106.5 mm (4.19 in)
Stroke 127 mm (5 in) 127 mm (5 in) 127 mm (5 in)
Displacement 6.8 L (415 in3) 6.8 L (415 in3) 4.5 L (275 in3)
FUEL:
Bio-Diesel Compatibility Spec C and up Spec C and up Spec C and up
Consumption - 60 Hz
Full Load N/A N/A N/A
Half Load N/A N/A N/A
Consumption - 50 Hz
Full Load 18.5 L/hr (4.9 gal/hr) 22.3 L/hr (5.9 gal/hr) 11.4 L/hr (3 gal/hr)
Half Load 9.8 L/hr (2.6 gal/hr) 11.7 L/hr (3.1 gal/hr) 6.4 L/hr (1.7 gal/hr)
Max Fuel Pump Lift
Minimum Fuel Inlet
- 3.5 psi - 3.5 psi - 3.5 psi
Pressure
Minimum Fuel Inlet
Pressure with Auxiliary - 8.5 psi - 8.5 psi - 8.5 psi
Pump

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6-2018 9. Specifications

DESCRIPTION MDDCH MDDCJ MDDCK

Maximum Fuel Height
above Injection Pump 3 m (10 ft) 3 m (10 ft) 3 m (10 ft)
Supply Pressure
Recommended Fuel Line
Size
Maximum Fuel Return
3 psi 3 psi 3 psi
Pressure (Restriction)
LUBRICATION:
Engine Oil Capacity 19.4 L (20.5 qt) 19.4 L (20.5 qt) 12.6 L (13.3 qt)
Maximum Angularity any
Direction
Continuous 30° 30° 30°
Intermittent 30° 30° 30°
COOLING:
Coolant Capacity 30 L (32 qt) 30 L (32 qt) 14 L (15 qt)
Coolant Flow Rate
60 Hz N/A N/A N/A
50 Hz 117 L/min (31 gal/min) 117 L/min (31 gal/min) 53 L/min (14 gal/min)
Raw Water Flow Rate
60 Hz N/A N/A N/A
50 Hz 68 L/min (18 gal/min) 68 L/min (18 gal/min) 68 L/min (18 gal/min)
Minimum Raw Water Inlet
- 4 psi - 4 psi - 4 psi
Pressure
Maximum Pressure Drop
across Keel Cooler Outlet 3 psi 3 psi 3 psi
and Inlet Connection
Heat Rejection to Coolant
60 Hz N/A N/A N/A
1148 Kcal/min (4554 1148 Kcal/min (4554 676 Kcal/min (2681
50 Hz
BTU/min) BTU/min) BTU/min)
Thermostat Opening
82 °C (180 °F) 82 °C (180 °F) 82 °C (180 °F)
Temperature
Thermostat Fully Open 95 °C (203 °F)
95 °C (203 °F) 95 °C (203 °F)
Temperature
Recommended Pressure
70 kPA (10 psi) 70 kPA (10 psi) 70 kPA (10 psi)
Cap
GENERATOR SET AIR
FLOW:
Combustion Air Flow 6.9 m3/min (244 ft3/min) 6.9 m3/min (244 ft3/min) 3.5 m3/min (124 ft3/min)

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9. Specifications 6-2018

DESCRIPTION MDDCH MDDCJ MDDCK

Heat Rejection to Ambient
60 Hz N/A N/A N/A
325 Kcal/min (1290 363 Kcal/min (1441
50 Hz 203 Kcal/min (805 Btu/min)
Btu/min) Btu/min)
EXHAUST:
Maximum Exhaust Back
2.2 in Hg 2.2 in Hg 2.2 in Hg
Pressure
Dry Exhaust Gas Flow 15.8 m3/min (558 ft3/min) 15.8 m3/min (558 ft3/min) 8.5 m3/min (300 ft3/min)
Dry Exhaust Temperature 411 °C (772 °F) 411 °C (772 °F) 455 °C (851 °F)
BATTERIES:
Nominal Battery Voltage 12/24 VDC 12/24 VDC 12/24 VDC
Minimum CCA Rating - SAE
800 Amps 800 Amps 640 Amps
@ 0 °C (32 °F) 12 VDC
Minimum CCA Rating - SAE
570 Amps 570 Amps 570 Amps
@ 0 °C (32 °F) 24 VDC
12 Volt Net Battery
Charging Output
Negative Ground (60 Hz) N/A N/A N/A
Isolated Ground (60 Hz) N/A N/A N/A
Negative Ground (50 Hz) 60 Amps 60 Amps 60 Amps
Isolated Ground (50 Hz) 70 Amps 70 Amps 70 Amps
24 Volt Net Battery
Charging Output
Negative Ground (60 Hz) N/A N/A N/A
Isolated Ground (60 Hz) N/A N/A N/A
Negative Ground (50 Hz) 40 Amps 40 Amps 40 Amps
Isolated Ground (50 Hz) 45 Amps 45 Amps 45 Amps
Starter Rolling Current
12V 920 Amps 920 Amps 780 Amps
24V 600 Amps 600 Amps 600 Amps
Maximum Starting Current
Resistance
12V 0.0012 ohms 0.0012 ohms 0.0012 ohms
24V 0.002 ohms 0.002 ohms 0.002 ohms
SIZE, WEIGHT, NOISE:
Weight without Sound
Shield:

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6-2018 9. Specifications

DESCRIPTION MDDCH MDDCJ MDDCK

Dry Weight 1320 kg (2910 lb) 1320 kg (2910 lb) 998 kg (2200 lb)
Weight with Sound
Shield:
Dry Weight 1433 kg (3161 lb) 1433 kg (3161 lb) 1098 kg (2420 lb)
Sound Level with Sound
70 dB(A) @ 50 Hz 70 dB(A) @ 50 Hz 72 dB(A) @ 50 Hz
Shield @ 1 meter

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9. Specifications 6-2018

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10 Maintenance Record
Record all periodic and unscheduled maintenance and service. See the Periodic Maintenance section for
more information.
Record the name, address, and phone number of your authorized Cummins service center.

TABLE 9. MAINTENANCE RECORD

HOUR
DATE METER MAINTENANCE OR SERVICE PERFORMED
READING

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10. Maintenance Record 6-2018

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Appendix A. Wiring Diagrams

Table of Contents
Figure 90. 0630-2755 Revision H (Sheet 1 of 4) ...................................................................................... 175
Figure 91. 0630-2755 Revision H (Sheet 2 of 4) ...................................................................................... 176
Figure 92. 0630-2755 Revision H (Sheet 3 of 4) ...................................................................................... 177
Figure 93. 0630-2755 Revision H (Sheet 4 of 4) ...................................................................................... 178

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Appendix A. Wiring Diagrams 6-2018

The drawings included in this section are representative. For current complete information,
refer to the drawing package that was shipped with the unit.

Copyright © 2018 Cummins Inc. 174 0981-0539 (Issue 9)

6-2018 Appendix A. Wiring Diagrams

A.1 Wiring Diagrams

FIGURE 90. 0630-2755 REVISION H (SHEET 1 OF 4)

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Appendix A. Wiring Diagrams 6-2018

FIGURE 91. 0630-2755 REVISION H (SHEET 2 OF 4)

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6-2018 Appendix A. Wiring Diagrams

FIGURE 92. 0630-2755 REVISION H (SHEET 3 OF 4)

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Appendix A. Wiring Diagrams 6-2018

FIGURE 93. 0630-2755 REVISION H (SHEET 4 OF 4)

Copyright © 2018 Cummins Inc. 178 0981-0539 (Issue 9)

Appendix B. Outline Drawings

Table of Contents
Figure 94. 0500-3799 Revision C (Sheet 1) .............................................................................................. 181
Figure 95. 0500-3799 Revision C (Sheet 2) .............................................................................................. 182
Figure 96. 0500-3799 Revision C (Sheet 3) .............................................................................................. 183
Figure 97. 0500-3799 Revision C (Sheet 4) .............................................................................................. 184
Figure 98. 0500-3800 Revision B (Sheet 1) .............................................................................................. 185
Figure 99. 0500-3800 Revision B (Sheet 2) .............................................................................................. 186
Figure 100. 0500-3800 Revision B (Sheet 3) ............................................................................................ 187
Figure 101. 0500-3800 Revision B (Sheet 4) ........................................................................................... 188

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Appendix B. Outline Drawings 6-2018

The drawings included in this section are representative. For current complete information,
refer to the drawing package that was shipped with the unit.

Copyright © 2018 Cummins Inc. 180 0981-0539 (Issue 9)

6-2018 Appendix B. Outline Drawings

B.1 MDDCA, MDDCB, MDDCC, MDDCF, MDDCG, MDDCK, MDDCL, MDDCM and MDDCN Outline Drawing

FIGURE 94. 0500-3799 REVISION C (SHEET 1)

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Appendix B. Outline Drawings 6-2018

FIGURE 95. 0500-3799 REVISION C (SHEET 2)

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6-2018 Appendix B. Outline Drawings

FIGURE 96. 0500-3799 REVISION C (SHEET 3)

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Appendix B. Outline Drawings 6-2018

FIGURE 97. 0500-3799 REVISION C (SHEET 4)

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6-2018 Appendix B. Outline Drawings

B.2 MDDCD, MDDCE, MDDCH, MDDCJ, MDDCP and MDDCR Outline Drawing

FIGURE 98. 0500-3800 REVISION B (SHEET 1)

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Appendix B. Outline Drawings 6-2018

FIGURE 99. 0500-3800 REVISION B (SHEET 2)

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6-2018 Appendix B. Outline Drawings

FIGURE 100. 0500-3800 REVISION B (SHEET 3)

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Appendix B. Outline Drawings 6-2018

FIGURE 101. 0500-3800 REVISION B (SHEET 4)

Copyright © 2018 Cummins Inc. 188 0981-0539 (Issue 9)

Appendix C. Wiring Harnesses

Table of Contents
Figure 102. 338-4439 Control MDD Wiring Harness (Sheet 1 of 2) ....................................................... 191
Figure 103. 338-4439 Control MDD Wiring Harness (Sheet 2 of 2) ....................................................... 192

0981-0539 (Issue 9) 189 Copyright © 2018 Cummins Inc.

Appendix C. Wiring Harnesses 6-2018

The drawings included in this section are representative. For current complete information,
refer to the drawing package that was shipped with the unit.

Copyright © 2018 Cummins Inc. 190 0981-0539 (Issue 9)

6-2018 Appendix C. Wiring Harnesses

C.1 MDD Wiring Harness

FIGURE 102. 338-4439 CONTROL MDD WIRING HARNESS (SHEET 1 OF 2)

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Appendix C. Wiring Harnesses 6-2018

FIGURE 103. 338-4439 CONTROL MDD WIRING HARNESS (SHEET 2 OF 2)

Copyright © 2018 Cummins Inc. 192 0981-0539 (Issue 9)

[Link]
Copyright © 2018 Cummins Inc. All rights reserved.
Cummins, Onan, and the "C" logo are registered trademarks of Cummins Inc. and its subsidiaries.
Other company, product, or service names may be trademarks or service marks of others.
Specifications are subject to change without notice.