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
121A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
20. Remove the rotor as follows:
a. Remove the stator and through-studs.
b. Remove the nut and flat washer on the rotor through-stud.
c. Use the 2 nuts locked together at the end of the rotor through-stud to
loosen and remove the through-stud from the crankshaft.
d. Thread in a rotor removal tool.
e. Using the groove in the end of the rotor removal rod, turn the rod with a
screwdriver until it bottoms in the crankshaft.
f. Thread in and tighten an M14 x 2.0 bolt against the rod until the rotor
breaks loose from the crankshaft.
FIGURE 65. ROTOR AND CRANKSHAFT
g. Remove the rotor removal tool.
h. Remove the rotor.
21. Remove the engine as follows:
a. Drain the engine oil. See the Engine Oil and Oil Filter Change section.
b. Remove the governor actuator linkage.
c. Remove the fuel line from the mixer assembly.
d. Remove the air box top and air filter.
e. Remove the 4 mixer mounting nuts.
f. Remove the 2 sets of nuts and washers that hold the air box base to the
engine cylinder heads.
g. Find the grommet connecting the crankcase ventilation port to the air box.
Remove the grommet and air box simultaneously.
h. Remove the intake manifold nuts mounting the manifold to the engine.
i. Remove the intake manifold and mixer.
j. Remove the remaining wiring harness connections, such as the oil level
sensor (if attached), oil pressure switch, engine oil heater (if present),
engine started, etc.