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
5. Maintenance10-2019
63A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
At each scheduled maintenance interval, perform all previous maintenance checks
that are due for scheduled maintenance.
Some of the factors that can affect the maintenance schedule are:
• Extremes in ambient temperature
• Exposure to elements
• Exposure to salt water
• Exposure to windblown dust or sand
Consult with your authorized Cummins service provider if the generator set will be
subjected to any extreme operating conditions, and determine if extra protection or
a reduction in service intervals is needed. Use the engine hours shown on the
system status screen to keep to keep an accurate log of all service performed for
warranty support. Perform all service at the time period indicated, or after the
number of operating hours indicated, whichever comes first.
Repair or replace worn, damaged, or improperly functioning components identified
during periodic maintenance procedures.
Periodic Maintenance Guidelines
Regularly performing the following periodic maintenance tasks greatly reduces the
chances of a generator set shutdown:
• Maintain an appropriate oil level.
• Keep battery connections clean and tight.
• Do not overload the generator set.
• Keep the air inlet and outlet openings clear.
Periodic Maintenance Schedule
Periodic maintenance is essential for top generator set performance. Use the
Maintenance Frequency table below as a guide for normal periodic maintenance.
• In hot and dusty environments, some maintenance procedures should be
performed more frequently, as indicated by the footnotes in the table.
• Maintenance, replacement or repair of emission control devices and systems
may be performed by any engine repair establishment or individual.
◦ Warranty work MUST be completed by your authorized Cummins Inc.
service provider.