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
84 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
NOTICE
Do not use anything other than a Scotch Brite pad as this will cause
damage to the slip rings and alternator.
4. Replace the brush block access cover and start the generator set.
5.12 Exercising the Generator Set
NOTICE
Audible engine RPM variation may be heard while there is no load applied.
This is normal and does not affect generator set performance.
Exercising the generator set re-lubricates the engine and removes oxides from
electrical contacts. The result is better starting, more reliable operation, and longer
generator set life.
The generator set exerciser is capable of automatically starting the generator set
and letting it run for a pre-set time. The frequency selections are:
• Weekly
• Bimonthly
• Monthly
• Never
Refer to the Exercise Settings on page 31 section of this manual for more
information on setting up the exerciser.
5.13 Complete System Test
NOTICE
Only authorized and qualified maintenance technicians who are familiar with
the equipment and its operation should carry out this test.
A complete system test is recommended to verify that the electrical system is
working properly. Testing the system once every 200 hours or every 2 years is
required to make sure the transfer switch will transfer the load to the generator set if
there is a utility power failure. For more information, see the transfer switch owner
manual.
To initiate a complete system test:
1. Before starting:
• Check the oil level.
• Verify that fuel related components, such as manual valves, outside of the
generator set are open.
• See the Checklist section in the installation manual.