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
160 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
ii. Verify that the magnet that is in the flywheel is still magnetic, is not
damaged, and/or has not been misplaced. Replace the flywheel if
necessary.
iii. If the magneto coil is still not functioning properly, replace it.
d. Inspect the spark plugs for damage and proper gap:
• Remove and inspect spark plugs. If they are damaged or dirty, replace
them.
• Measure the spark plug gap. Re-gap if necessary.
Code 27 - Voltage Sense Lost
Logic: The generator set frequency is greater than 40 Hz and voltage sensed is
less than 5 VAC on one or both lines. (The control senses if one line is lost or
disconnected.)
Possible Causes:
• Generator set loads
• Alternator windings
• Wire connections
Diagnosis & Repair:
1. Check the last fault recorded.
• If this fault has not been repaired, troubleshoot that fault.
2. Measure the AC voltage.
3. Disconnect the generator set control P1 connector.
4. 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.
5. 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.
6. When reconnecting the harness plug to the connector, ensure that the pair are
fully seated next to each other.
7. Reconnect the P1 connector and test-run the generator set for fault occurrence.