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
79A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
5.7 DC Electrical System
WARNING
Combustible Gases
Ignition of battery gases is a fire and explosion hazard which can cause
severe personal injury or death.
Do not smoke, or switch the trouble light ON or OFF near a battery. Touch a
grounded metal surface first before touching batteries to discharge static
electricity. Stop the generator set and disconnect the battery charger before
disconnecting battery cables. Using an insulated wrench, disconnect the
negative (–) cable first and reconnect it last.
1. Check the harness connections. If any harness connections are damaged,
contact your service representative.
FIGURE 43. CHECK HARNESS CONNECTIONS
2. Check the terminals on the batteries for clean and tight connections. Loose or
corroded connections create resistance, which can hinder starting. Clean and
reconnect the battery cables if loose, using an insulated wrench.
5.8 Batteries
Batteries are an essential part of any standby generator set system. A significant
amount of generator set failures are due to battery issues.
It is therefore vital that batteries are stored, commissioned, and maintained as
detailed here. Reference should also be made to the battery manufacturer’s
instructions.
Maintenance free batteries (if supplied with the generator set) need no maintenance
for commissioning.