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
1. IMPORTANT SAFETY INSTRUCTIONS 10-2019
6 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
FIGURE 1. HATCHED AREAS
Make sure this consideration is captured in your risk assessment.
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 jewelry 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 Locking the
Generator Set Out of Service 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.
Guidelines to follow when working on energized electrical systems: