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
155A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
5. Disconnect the generator set control P1 connector.
6. Verify that the P1 and P2 pin sockets are fully inserted and inspect the pin
socket condition for corrosion and acceptable condition of contact wipers. To
check contact wipers, use one of the devices below:
• A mating pin connector
• A pin gauge the same size as the mating control connector pin (0.045 in)
• Any suitable device that will not damage the inside contact wipers of the
pin socket
If necessary:
• Clean, repair or replace any pin sockets.
• Fully insert any partially inserted pin sockets.
7. Inspect the condition of P1 and P2 pins on the control board. If they are
damaged or severely corroded, clean or repair if possible, or replace the control
board.
8. When reconnecting the harness plug to the connector, ensure that the pair are
fully seated next to each other.
9. Reconnect the P1 connector and test-run the generator set for fault occurrence.
• Repair or replace pins in the connector if necessary.
10. Check for air filter cleanliness.
• Replace the air filter if necessary.
11. Check for a damaged exhaust system and listen for any unusual noises.
• Repair or replace exhaust components if necessary.
12. Propane models only:
a. When ambient temperatures are less than 40 °F (34.4 °C), vapor
withdrawal propane tanks should be at least half full to provide the proper
vaporization rate.
b. Propane having more than 2.5% butane will not vaporize in ambient
temperatures at less than 32 °F (0 °C); use HD-5 grade propane.
c. Verify tank level and fuel line conditions.
13. Measure steady DC voltage at the fuel solenoid while the generator set is
running.
• Repair wiring if necessary.
14. Check the generator set fuel lines for damage.
• Replace the fuel line if necessary.
15. Measure the fuel supply pressures.
16. Check the governor actuator, actuator linkage, and throttle shaft for free smooth
motion without slop. Verify that the actuator is opening the throttle while
cranking.