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
71A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
20. Reconnect the cables and battery charger:
a. Reconnect the engine battery cables, positive (+) cable first.
b. Reconnect the battery charger to its AC power source.
21. Reconnect the oil heater AC power or energize its AC circuit.
22. Operate the generator set with no load for approximately 5 minutes to check for
leaks at the oil filter or oil drain hose.
23. Shut down the generator set, wait 5 minutes, and then confirm that the correct
oil level is in the pan.
24. Check for leaks and repair any that are identified.
25. Dispose of the used oil and oil filter according to local environmental
regulations.
26. Re-install the access panels. Torque the fasteners 5.0–6.6 Nm (3.5–5.0 ft-lb).
27. Restore the original generator set settings.
28. Close the generator set breaker.
5.4 Engine Valve Clearance
1. Make sure the generator set is shut down and disabled:
a. Press the generator set's red STOP button on the local display to stop the
generator set. Allow the generator set to thoroughly cool to the touch.
b. Turn off and disconnect the battery charger from the AC source before
disconnecting the battery cables.
c. Disconnect the negative (–) cable from the battery first and secure it from
contacting the battery terminals to prevent accidental starting. Then
disconnect the positive cable.
NOTICE
Once work is complete, reconnect the negative (–) battery cable last.
2. Open the hood.
3. Remove the control access panel.
4. Remove the intake air and exhaust panels.