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
7. Troubleshooting10-2019
137A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
7.7 Engine Flywheel Battery Charger
Troubleshooting
WARNING
Combustible Gases
Batteries can explode, causing severe skin and eye burns, and can release
toxic electrolytes.
Do not dispose of the battery in a fire, because it is capable of exploding. Do
not open or mutilate the battery.
WARNING
Electric Shock Hazard
Batteries present the risk of high short circuit current.
Remove watches, rings, or other metal objects. Use tools with insulated
handles.
NOTICE
Servicing of batteries must be performed or supervised by personnel
knowledgeable of batteries and the required precautions. Keep unauthorized
personnel away from batteries.
TABLE 20. TROUBLESHOOTING
Problem Possible Causes Action
No Charger Output
and Low Battery
Blown fuse
Replace the 20 Amp fuse between
the voltage regulator and magnetos
in the wiring. See the figure below
for the fuse location.
Low Battery
Voltage (Less
Than 13.2 VDC)
Recent utility outage
Replace the battery if the voltage is
not increasing with positive charge
current.
Failed generator set flywheel
charger
High Battery
Voltage (Greater
than 15 VDC)
Charger failure
Determine if the overcharge is from
the utility-powered charger or from
the generator set 9 Amp flywheel
battery charger. Replace the
appropriate battery charger.