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
8 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
AC Disconnect Sources
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or
death.
The equipment may have more than one source of electrical energy.
Disconnecting one source without disconnecting the others presents a
shock hazard. Before starting work, disconnect the equipment, and verify
that all sources of electrical energy have been removed.
1.5 Fuel and Fumes Are Flammable
Fire, explosion, and personal injury or death can result from improper practices.
• DO NOT permit any flame, cigarette, pilot light, spark, arcing equipment, or
other ignition source near the generator set or fuel system.
• Fuel lines must be adequately secured and free of leaks. Fuel connection at the
engine should be made with an approved flexible line. Do not use copper piping
on flexible lines because copper will become brittle if continuously vibrated or
repeatedly bent.
• Be sure all fuel supplies have a positive shutoff valve.
• Be sure the battery area has been well-ventilated prior to servicing near it.
Lead-acid batteries emit a highly explosive hydrogen gas that can be ignited by
arcing, sparking, smoking, etc.
Gaseous Fuels
Natural gas is lighter than air, and will tend to gather under covered areas.
Do Not Operate in Flammable and Explosive Environments
Flammable vapor can cause an engine to over speed 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.
1.6 Exhaust Gases Are Deadly
• Provide an adequate exhaust system to properly expel discharged gases away
from enclosed or sheltered areas, and areas where individuals are likely to
congregate. Visually and audibly inspect the exhaust system daily for leaks per
the maintenance schedule. Make sure that exhaust manifolds are secured and
not warped. Do not use exhaust gases to heat a compartment.