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 INSTRUCTIONS10-2019
7A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
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 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.
• Make sure that an accompanying person who can undertake a rescue is
nearby.
AC Supply and Isolation
NOTICE
Local electrical codes and regulations (for example, BS EN 12601:2010
Reciprocating internal combustion engine driven generating sets) may
require the installation of a disconnect means for the generator set, either on
the generator set or where the generator set conductors enter a facility.
NOTICE
The AC supply must have the correct over current and earth fault protection
according to local electrical codes and regulations. This equipment must be
earthed (grounded).
It is the sole responsibility of the customer to provide AC power conductors for
connection to load devices and the means to isolate the AC input to the terminal
box; these must comply with local electrical codes and regulations. Refer to the
wiring diagram supplied with the generator set.
The disconnecting device is not provided as part of the generator set, and Cummins
accepts no responsibility for providing the means of isolation.