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
147A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
Possible Causes:
• Low/high oil level
• Faulty oil pressure switch
• Faulty oil pressure relief valve in engine
• Harness is faulty (unintentional ground in circuit)
• Faulty oil pump
Diagnosis and Repair:
1. Check the last fault recorded.
• If this fault has not been repaired, troubleshoot that fault.
2. Measure the oil level.
• Add or drain oil if necessary.
3. Disconnect the plug from the oil pressure switch and measure continuity from
P1-6 and GND. If there is circuit continuity, find and repair the short to ground
in the harness from P1-6 to the oil switch connector.
4. Verify switch operation:
a. Check for continuity (ground) across the switch when the generator set is
not running.
b. Check for open across the switch when the generator set is running.
c. Replace the switch if it is not working correctly.
5. Repair or replace the harness if necessary.
6. Measure oil pressure with a mechanical gauge.
• If oil pressure is low and needs to be corrected, replace the engine.
Code 4 - Overcrank
Logic: The generator set control did not sense alternator quad winding frequency
after cycle crank (30 seconds of cranking and 15 seconds between each crank
attempt for a total of 3 crank attempts).
Possible Causes:
• Generator set did not start
• Fuel supply
• Air fuel mixture
• Wire connections
• Starter
• Ignition system
• Battery
• Battery Connections
• Battery heater (if applicable)