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
81A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
Fire Hazard
WARNING
Combustible Gases
Lead acid batteries present a risk of fire because they generate
hydrogen gas.
Do not smoke near the batteries. Do not cause flame or spark in the
battery area. Discharge static electricity from your body before
touching batteries by first touching a grounded metal surface.
WARNING
Before disconnecting a battery, always remove power from the AC
powered battery charger.
WARNING
When putting a battery into service on a generator set, connect the
negative lead LAST; when removing the battery, disconnect the
negative lead FIRST.
Vented Batteries
WARNING
Toxic Hazard
The electrolyte in vented batteries is a dilute sulfuric acid that is
harmful to the skin and eyes. It is also electrically conductive and
corrosive.
Always:
1. Wear full eye protection and protective clothing;
2. If the electrolyte contacts the skin, wash it off immediately with
water;
3. If the electrolyte contacts the eyes, flush them thoroughly and
immediately with water and seek medical attention; and
4. Wash spilled electrolyte down with an acid neutralizing agent. A
common practice is to use a solution of one pound (500 grams)
bicarbonate of soda (also known as baking soda or sodium
bicarbonate) to one gallon (4 liters) of water.
5. Continue to add the bicarbonate of soda solution until the evidence
of reaction (that is, foaming) has stopped.
6. Flush the resulting liquid with water and dry the area.