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. Troubleshooting 10-2019
150 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
20. Measure field, quadrature, and main winding resistance.
• Clean the slip rings, replace the brushes, repair the harness, and replace
the rotor and stator assembly if necessary.
21. Check the battery heater to make sure if it is functioning properly (if applicable).
a. Verify that the heater thermostat is functioning properly.
b. If a battery heater is recommended for ambient temperature and not
installed, install a battery heater.
22. Check that correct oil is being used for ambient conditions. If not, change oil.
a. If present, verify that oil heater is functioning properly. Repair if necessary.
b. If an oil heater is recommended and not installed, install an oil heater.
c. Verify that heater thermostat is functioning properly.
23. Measure quad voltage during cranking. If below 15 VAC during cranking,
inspect the excitation system. Field voltage should equal battery voltage (12
VDC nominal) during cranking. If not, replace the generator set control.
Code 12 - Overvoltage
Logic:
• Instantaneous Fault: AC voltage S1-S2 greater than 300 VAC
• Delayed Fault: AC voltage line-to-line greater than 268 VAC, but less than 300
VAC for 3 continuous seconds.
Possible Causes:
• Generator set loads
• Wire connections
• Alternator windings
• Faulty voltage regulator
• Sticking governor linkage
Diagnosis & Repair:
1. Check the last fault recorded.
• If this fault has not been repaired, troubleshoot that fault.
2. Measure and verify the AC voltage at the generator set circuit breaker and at
pins P1-34 and P1-35.
3. Verify the AC frequency on the display, then measure it on a digital volt
ohmmeter. Compare the two measurements to determine if the control is
measuring frequency correctly.
• If the compared measurements are not consistent, replace the control
board.
4. Cycle loads to determine if a particular load causes fault.
• Diagnose faulty load if necessary.