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
116 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
NOTICE
The Automatic Voltage Regulator (AVR) contains electronic
components which would be damaged by high voltage applied during
insulation resistance tests. The AVR must be disconnected before
doing any insulation resistance test. Temperature sensors must be
grounded to earth before doing any insulation resistance test.
Damp or dirty windings have a lower electrical resistance and could be
damaged by insulation resistance tests at high voltage. If in doubt, test
the resistance at low voltage (500 V) first.
Alternator performance depends on good electrical insulation of the windings.
Electrical, mechanical and thermal stresses, and chemical and environmental
contamination, cause the insulation to degrade. Various diagnostic tests
indicate the condition of insulation by charging or discharging a test voltage on
isolated windings, measuring current flow, and calculating the electrical
resistance by Ohm’s law.
When a DC test voltage is first applied, three currents can flow:
• Capacitive Current: To charge the winding to the test voltage (decays to
zero in seconds),
• Polarizing Current: To align the insulation molecules to the applied
electric field (decays to near-zero in ten minutes), and
• Leakage Current: Discharge to earth where the insulation resistance is
lowered by moisture and contamination (increases to a constant in
seconds).
For an insulation resistance test, a single measurement is made one minute
after a DC test voltage is applied, when capacitive current has ended. For the
polarization index test, a second measurement is made after ten minutes. An
acceptable result is where the second insulation resistance measurement is at
least double the first, because the polarization current has decayed. In poor
insulation, where leakage current dominates, the two values are similar. A
dedicated Insulation Tester takes accurate, reliable measurements and may
automate some tests.
Safety
DANGER
Live Electrical Conductors
Live electrical conductors can cause serious injury or death by electric
shock and burns.
To prevent injury and before removing covers over electrical
conductors, isolate the generator set from all energy sources, remove
stored energy and use lock out/tag out safety procedures.