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
159A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
10. Check for air filter cleanliness.
• Replace the air filter if necessary.
11. Propane models only:
• 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.
• 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.
• Verify tank level and fuel line conditions.
12. Check the generator set fuel lines for damage.
• Replace the fuel line if necessary.
13. Measure the fuel supply pressures.
14. Check the intake manifold and gaskets for air leaks.
• Tighten the fasteners.
• Replace the gaskets and manifold if necessary.
15. Check the mixer gaskets for leaks.
• Tighten the fasteners within the air box.
• Replace the 2 gaskets at the mixer if necessary.
16. Check for a damaged exhaust system and listen for any unusual noises.
• Repair or replace exhaust components if necessary.
17. Verify the actuator function by applying DC voltage to the terminals.
• Replace the actuator if necessary.
18. 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.
19. Check the engine ignition system:
a. Verify that the spark plug leads are fully installed on the spark plugs.
Reconnect them if necessary.
b. Inspect the spark plug leads. Replace worn or damaged leads.
NOTICE
Spark plug leads are only available as part of the coil assembly.
c. Check the magneto output:
i. Using a spark tester, verify that the magneto coils are providing
acceptable output. If the output is not acceptable, verify proper
magneto gap (see Section 2.5 on page 17), and re-gap if necessary.