Service Manual
Table Of Contents
- Table of Contents
 - 1. IMPORTANT SAFETY INSTRUCTIONS
- 1.1 Warning, Caution, and Note Styles Used in This Manual
 - 1.2 General Information
 - 1.3 Generator Set Safety Code
 - 1.4 Electrical Shocks and Arc Flashes Can Cause Severe Personal Injury or Death
 - 1.5 Fuel and Fumes Are Flammable
 - 1.6 Exhaust Gases Are Deadly
 - 1.7 The Hazards of Carbon Monoxide
 - 1.8 Earth Ground Connection
 
 - 2. Introduction
 - 3. Startup
 - 4. Operation
 - 5. Maintenance
- 5.1 Maintenance Safety
 - 5.2 Periodic Maintenance
 - 5.3 Engine Oil
 - 5.4 Engine Valve Clearance
 - 5.5 Normal Duty Air Cleaner Element Replacement
 - 5.6 Exhaust System Maintenance
 - 5.7 DC Electrical System
 - 5.8 Batteries
 - 5.9 Spark Plugs
 - 5.10 Cleaning the Generator Set Housing
 - 5.11 Cleaning the Slip Rings
 - 5.12 Exercising the Generator Set
 - 5.13 Complete System Test
 
 - 6. Service
 - 7. Troubleshooting
- 7.1 Troubleshooting Procedures
 - 7.2 Safety Considerations
 - 7.3 GATRR Troubleshooting Approach
 - 7.4 Tools and Parts Required
 - 7.5 Troubleshooting with the Local or Remote Displays
 - 7.6 Utility-Powered Battery Charger Troubleshooting
 - 7.7 Engine Flywheel Battery Charger Troubleshooting
 - 7.8 Fuel Shutoff Solenoid Valve
 - 7.9 Compression Test Procedure
 - 7.10 Connecting with the InPower Service Tool
 - 7.11 Troubleshooting by Symptom
 - 7.12 Troubleshooting with Fault Codes
 - 7.13 Remote Monitoring Communication Troubleshooting
 
 - Appendix A. Wiring Diagrams
 
6. Service 10-2019
128 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
Area Component Metric Imperial
Enclosure Muffler Mounting Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb
Enclosure Oil Cooler Bolts 5.6–6.6 Nm 50–58 in-lb
Enclosure Service Access Panel Bolts 5.6–6.6 Nm 50–58 in-lb
Enclosure Solenoid Mounting Bracket Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb
Engine Airbox Cover Bolts 3.2–4.0 Nm 28–35 in-lb
Engine Airbox Mounting Brackets Bolts 3.2–4.0 Nm 28–35 in-lb
Engine Airbox to Mixer/Throttle Body Nuts 3.2–4.0 Nm 28–35 in-lb
Engine Crankcase Reed Valve Cover Bolts 8–12 Nm 71–106 in-lb
Engine Dipstick (Shipped Separately) 9.8–11.9 Nm* 7.2–8.8 ft-lb*
Engine Exhaust Manifold Nuts 33–40 Nm 24.3–29.5 ft-lb
Engine Flywheel Nut 90–105 Nm 66.4–77.4 ft-lb
Engine Governor Actuator Bracket to Engine Bolts 5.0–6.2 Nm 44–55 in-lb
Engine Governor Actuator Mounting Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb
Engine Battery Charge Alternator Mounting Bolts 8–12 Nm 71–106 in-lb
Engine Head Bolts 50–55 Nm 36.9–40.6 ft-lb
Engine Rocker Arm Retainer Nut (Remove For
Compression Test)
8–12 Nm 71–106 in-lb
Engine Starter Mounting Bolts 25–30 Nm 18.4–22.1 ft-lb
Engine Valve Cover Bolts 8–12 Nm 71–106 in-lb
Engine Voltage Regulator Mounting Nuts 8–12 Nm 71–106 in-lb
Engine Intake Manifold Nuts (Locking Feature of Nut
Faces Outward)
11–14 Nm 8–10.3 ft-lb
Engine Isolator Bolts - Engine 24–29 Nm 17.7–24.1 ft-lb
Engine Mixer Fuel Inlet Fitting/Lock Nut 58.3–77.3 Nm* 43–57 ft-lb*
Engine Reed Valve Bolt 8–12 Nm 71–106 in-lb
Engine Shield Bolts (Left and Right Side) 8–12 Nm 71–106 in-lb
Engine Spark Plugs 25–30 Nm 18.4–22.1 ft-lb
Engine Starter B+ Terminal 8–10 Nm* 71–89 in-lb*
Other Battery Tray Bolt 3.2–4 Nm 28–35 in-lb
*See the special instructions in the Alternator and Engine Removal and Installation
section.










