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
80 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
Storage
Batteries must be stored in a cool, dry, well-ventilated place, in the upright position,
and with the vent caps securely in place.
Batteries must never be stacked on top of each other and must be protected from
the floor by a wooden pallet or suitably thick cardboard sheet.
General Precautions for Maintenance-Free Batteries
Handling and proper use of batteries is not hazardous if the correct precautions are
observed and personnel are trained in their use.
WARNING
Arcing Hazard
Laying tools or metal objects across the battery can cause arcing that may
ignite battery gases causing explosions resulting in personal injury.
Never lay tools or metal objects across the top of the battery.
WARNING
Electric Shock Hazard
Voltages and currents present an electrical shock hazard that can cause
severe burns or death.
Use tools with insulated handles to prevent the risk of electric shock.
CAUTION
Toxic Hazard
Electrolyte is a dilute sulphuric acid that is harmful to the skin and eyes. It is
electrically conductive and corrosive.
Wear full eye protection and protective clothing. If electrolyte contacts the
skins, wash it off immediately with water. If electrolyte contacts the eyes,
flush thoroughly and immediately with water and seek medical attention.
Wash spilled electrolyte with an acid neutralizing agent.
NOTICE
Keep batteries upright to prevent spillage.