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. Service10-2019
123A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
iii. Align the stator through-bolts with the engine mounting hole, and
thread them into the holes. Torque the stator through-bolts by hand.
iv. Insert the rotor through-bolt and thread it into the engine crankshaft by
hand until the bolt bottoms out.
v. While viewing from the non-drive end, torque the stator through-bolt
nuts as follows, with a progression of 2 o’clock, 8 o’clock, 10 o’clock,
and 4 o’clock each time:
Initial 27–33 Nm (19.9–24.3 ft-lb)
Final 38–42 Nm (28–31 ft-lb)
vi. Visually check the gap between the rotor and stator laminations at the
end bell end of the alternator. The gap should be nearly identical all
the way around. If the gap is not nearly identical, loosen the nuts on
the 4 studs and repeat the tightening procedure.
b. For a rotor-only installation:
i. Slide the rotor onto the engine taper.
ii. Insert the rotor through-bolt and thread it into the engine crankshaft by
hand until it bottoms out.
c. For a stator-only installation:
i. Slide the stator/end bell over the rotor and align the stator through-
bolts to the engine holes to properly seat the rotor bearing. Do not
allow contact between the stator and the rotor.
ii. Thread the stator through-bolts in to the engine and hand-tighten.
5. Install the alternator isolator washers and nuts. Torque the nuts to 24–29 Nm
(17.7–24.1 ft-lb).
6. Install the governor actuator linkage onto the throttle shaft. See the Governor
Actuator Removal and Installation section.
7. Install the exhaust manifold using new gaskets (see the parts manual). Torque
the nuts to 33–40 Nm (24.3–29.5 ft-lb).
8. Install the intake manifold with new gaskets (see the parts manual).
a. Place clamp over air box grommet while positioning the air box over the
engine, aligning the grommet over the engine breather port.
b. Push down on the bottom of the air box to seat the grommet and clamp
over the engine breather.
c. Install nuts and washers in the heads and through the brackets on the air
box (do not tighten the brackets yet and make sure each side contains a
washer).
d. Install the 4 studs into the intake manifold for mounting the mixer.
e. Position the gasket and mixer onto the intake manifold.