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
129A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
6.6 Placing the Generator Set Back in Service
If the control board is replaced, it will be necessary to configure the replacement
control board. See the "Generator Config" Screen section for more information.
When all service and maintenance is completed on the generator set, the generator
set control should be set to standby if it is safe to do so, or to an alternate state if
requested by the customer.
6.7 Transfer Switch
WARNING
Interconnecting the generator set and the public utility can lead to the
electrocution of personnel working on the utility lines, damage to equipment
and fire. An approved switching device must be used to prevent
interconnections.
For information regarding servicing the transfer switch, see the appropriate transfer
switch owner manual.
6.8 Line Circuit Breaker Troubleshooting
WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal
injury or death.
Isolate all auxiliary supplies and use an insulated wrench to disconnect the
starting battery cables, negative (–) cable first. Make sure the generator set
is safely locked out of service to prevent disconnecting wires while the set is
running
1. Make sure the generator set is shut down and disabled:
a. Press the generator set's red STOP button on the local display to stop the
generator set. Allow the generator set to thoroughly cool to the touch.
b. Turn off and disconnect the battery charger from the AC source before
disconnecting the battery cables.
c. Disconnect the negative (–) cable from the battery and secure it from
contacting the battery terminals to prevent accidental starting.
d. Once work is complete, reconnect the negative (-) battery cable last.
2. Disconnect the leads going into and out of the circuit breaker. There are two
sets of leads:
• One set of two leads from the alternator that is installed in the lugs at the
top of the breaker (L1 and L2)