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
10 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
1.7 The Hazards of Carbon Monoxide
Carbon monoxide (CO) is an odorless, colorless, tasteless and non-irritating gas.
You cannot see it or smell it. Red blood cells, however, have a greater affinity for
CO than for oxygen. Therefore, exposure even to low levels of CO for a prolonged
period can lead to asphyxiation (lack of oxygen) resulting in death. Mild effects of
CO poisoning include eye irritation, dizziness, headaches, fatigue and the inability to
think clearly. More extreme symptoms include vomiting, seizures and collapse.
Engine-driven generator sets produce harmful levels of carbon monoxide that can
injure or kill you.
Special Risks of CO near the Home
WARNING
Toxic Gases
Carbon monoxide (CO) gas can cause nausea, fainting, or death. Residents
can be exposed to lethal levels of CO when the generator set is running.
Depending on air temperature and wind, CO can accumulate in or near the
home.
To protect yourself and others from the dangers of CO poisoning, it is
recommended that reliable, approved, and operable CO detector alarms are
installed in proper locations in the home as specified by their manufacturer.
Protecting Yourself from CO Poisoning
• Locate the generator set in an area where there are no windows, doors, or
other access points into the home.
• Make sure all CO detectors are installed and working properly.
• Pay attention for signs of CO poisoning.
• Check the exhaust system for corrosion, obstruction, and leaks every time you
start the generator set and every eight hours when you run it continuously.
1.8 Earth Ground Connection
The neutral of the generator set may be required to be bonded to earth ground at
the generator set location, or at a remote location, depending on system design
requirements. Consult the engineering drawings for the facility or a qualified
electrical design engineer for proper installation.
NOTICE
The end user is responsible to make sure that the ground connection point
surface area is clean and free of rust before making a connection.