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
6. Service10-2019
111A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
Alternator Heater
DANGER
Live Electrical Conductors
Live electrical conductors can cause serious injury or death by electric
shock and burns.
To prevent injury and before removing covers over electrical conductors,
isolate the generator set from all energy sources, remove stored energy and
use lock out/tag out safety procedures.
Power to the alternator heater is supplied from a separate AC source. The
alternator heater raises the air temperature around the windings to deter
condensation forming in humid conditions when the generator set is not operating.
Alternator Temperature Switch
The alternator temperature switch helps protect the generator set when unusual
conditions occur such as severe blockage of the air intake or air discharge panels.
The temperature switch is fastened to the lower stator through-bolt on the non-drive
end of the alternator and on the exhaust side of the enclosure near the brush block
maintenance panel. The temperature switch contacts are normally closed. The
switch contacts open at 197 – 210 °F (92 – 99 °C). If the switch contacts open, the
generator set control will turn off the generator set.
Sealed Bearings
Inspect sealed-for-life bearings periodically. Check for signs of wear, fretting or
other detrimental features. Damage to seals, grease leakage or discoloration of the
bearing races indicate that the bearing may be failing.
Brush Block/Slip Ring Service
1. Remove the brush block cover.
2. Disconnect the field leads from the brush block (F1, F2).
3. Remove the two mounting screws.
4. Withdraw the brush block from the alternator end bell.
5. Inspect the brush block:
a. If either brush is shorter than 11 mm (7/16 inch), binds in the brush block,
or is damaged in any way, replace the brush block assembly.
i. When re-installing the brush block, make sure to keep the brushes in
the retracted position by using a wire through the hole in the end of the
brush block. A new brush block assembly will come with this wire in
place.
ii. After bolting the brush block securely in place, remove the wire.