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
83A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
NOTICE
Never allow a battery to become completely flat (fully discharged), or to
stand in a discharged condition, or damage will result.
Battery Replacement
WARNING
Combustible Liquid
Burning the battery may cause an explosion. Damage to the casing will
release electrolytes which is harmful to the skin and eyes.
When disposing of a battery, do not mutilate or burn it. Comply with all local
health and safety regulations/codes during handling or disposal.
Always replace the starting battery with the same number and type (e.g., vented,
lead acid, maintenance free) as listed in the specifications section of this document.
Properly dispose of battery in accordance with local environment agency
requirements.
Always use correct handling techniques to lift and move a battery.
5.9 Spark Plugs
Spark plugs are designed to last the useful life of the generator set. If a spark plug
malfunction is suspected, remove and inspect the condition of each spark plug.
Check for excessive corrosion, oil accumulation and soot deposits. Refer to the
Model Specifications section for spark plug gap and installation torque.
5.10 Cleaning the Generator Set Housing
The housing of the generator set housing can be damaged by pressure washing or
solvents and other cleaning agents. Only use soap and water or an “all citrus
degreaser" to clean the housing.
5.11 Cleaning the Slip Rings
Over time the slip rings can have a build up of corrosion which needs to be cleaned
off in order to have normal operation of the alternator. To clean the slip rings:
1. Press the generator set's red STOP button on the local display to disable the
generator set. The generator set stops immediately and both remote and
standby modes are disabled.
2. Locate and remove the brush block access cover (see Section 6.5 on page
109.
3. Use a Scotch Brite pad and clean off build up on the slip rings. If necessary,
rotate the alternator by hand while cleaning.