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
164 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
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.
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.
19. 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.
20. 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.
21. Check the condition of the slip rings and brushes and clean or replace if
necessary.
a. Check brush alignment:
• Inspect brush wear on the slip rings and verify brush misalignment is
toward the windings.
• If misalignment is toward the bearing, the cause is not a tolerance
issue, but more likely the result of the end bell not being seated
properly during assembly.
• Inspect for cause and repair if necessary.
b. 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.
c. 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 35 - Control Card Failure
Logic: EEPROM (programming variables) error during self-test
Possible Causes: Faulty program