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. Maintenance 10-2019
78 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
6. Re-install the access panel and tighten the screws. Torque 3.5 - 5.0 ft-lb (5.0 -
6.6 Nm).
7. Reconnect the battery and restore the original generator set settings.
5.6 Exhaust System Maintenance
WARNING
Hot Exhaust Components
Exhaust components become very hot when the generator set is in use and
remain hot for a period of time after the generator set has been shut down.
These components can cause severe personal injury or death from contact.
Allow these components to cool completely before performing any
maintenance tasks.
WARNING
Inhalation of Exhaust Gases
Inhalation of exhaust gases can result in serious personal injury or death.
Be sure deadly exhaust gas is piped outside and away from windows, doors
or other inlets to buildings. Do not allow to accumulate in habitable areas.
WARNING
Moving Parts
Moving parts can cause severe personal injury or death.
Use extreme caution around moving parts, etc.
With the generator set operating, listen for any unusual noises coming from the
exhaust system, focusing on the exhaust manifold, muffler, and exhaust pipe. If
detected, allow the unit to cool and immobilize the generator set by disconnecting
the battery. Lift the cover, making sure it locks into the upward position, and remove
the panels over the alternator. Look for any leaks at all connections, welds, gaskets,
and joints. Repair as necessary and reconnect the battery.