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
128 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
Area Component Metric Imperial
Enclosure Muffler Mounting Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb
Enclosure Oil Cooler Bolts 5.6–6.6 Nm 50–58 in-lb
Enclosure Service Access Panel Bolts 5.6–6.6 Nm 50–58 in-lb
Enclosure Solenoid Mounting Bracket Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb
Engine Airbox Cover Bolts 3.2–4.0 Nm 28–35 in-lb
Engine Airbox Mounting Brackets Bolts 3.2–4.0 Nm 28–35 in-lb
Engine Airbox to Mixer/Throttle Body Nuts 3.2–4.0 Nm 28–35 in-lb
Engine Crankcase Reed Valve Cover Bolts 8–12 Nm 71–106 in-lb
Engine Dipstick (Shipped Separately) 9.8–11.9 Nm* 7.2–8.8 ft-lb*
Engine Exhaust Manifold Nuts 33–40 Nm 24.3–29.5 ft-lb
Engine Flywheel Nut 90–105 Nm 66.4–77.4 ft-lb
Engine Governor Actuator Bracket to Engine Bolts 5.0–6.2 Nm 44–55 in-lb
Engine Governor Actuator Mounting Bolts 9.8–11.9 Nm 7.2–8.8 ft-lb
Engine Battery Charge Alternator Mounting Bolts 8–12 Nm 71–106 in-lb
Engine Head Bolts 50–55 Nm 36.9–40.6 ft-lb
Engine Rocker Arm Retainer Nut (Remove For
Compression Test)
8–12 Nm 71–106 in-lb
Engine Starter Mounting Bolts 25–30 Nm 18.4–22.1 ft-lb
Engine Valve Cover Bolts 8–12 Nm 71–106 in-lb
Engine Voltage Regulator Mounting Nuts 8–12 Nm 71–106 in-lb
Engine Intake Manifold Nuts (Locking Feature of Nut
Faces Outward)
11–14 Nm 8–10.3 ft-lb
Engine Isolator Bolts - Engine 24–29 Nm 17.7–24.1 ft-lb
Engine Mixer Fuel Inlet Fitting/Lock Nut 58.3–77.3 Nm* 43–57 ft-lb*
Engine Reed Valve Bolt 8–12 Nm 71–106 in-lb
Engine Shield Bolts (Left and Right Side) 8–12 Nm 71–106 in-lb
Engine Spark Plugs 25–30 Nm 18.4–22.1 ft-lb
Engine Starter B+ Terminal 8–10 Nm* 71–89 in-lb*
Other Battery Tray Bolt 3.2–4 Nm 28–35 in-lb
*See the special instructions in the Alternator and Engine Removal and Installation
section.