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
125A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
17. Install the remaining alternator ground strap bolt with the following parts on the
skid in the following order:
a. Star washer
b. Flat washer
c. Alternator ground strap
d. Flat washer
e. Bolt
Torque the bolt to 5–6.2 Nm (44–55 ft-lb).
18. Route the alternator leads through the correct CT and onto the circuit breaker.
Torque the fasteners to 4–5 Nm (35–44 in-lb).
19. Attach the oil cooler to the intake-side inner enclosure panel. Torque the bolts
to 5.6–6.6 Nm (50 –58 in-lb).
20. Install the alternator-end inner enclosure panel, on which the muffler is
mounted. Torque the bolts to 5.6–6.6 Nm (50–58 in-lb).
21. Install the exhaust-side inner enclosure panel. Torque the bolts to 5.6 –6.6 Nm
(50–58 in-lb).
22. Install the muffler. Torque the mounting bolts to 9.8–11.9 Nm (7.23–8.78 ft-lb).
Torque the clamp nuts to 13.9–16.8 Nm (10.25–12.4 ft-lb).
23. Install the alternator fan. Torque the nut on the through-stud to 113–139 Nm
(83.62–102.86 ft-lb).
NOTICE
To prevent alternator rotation when tightening the rotor nut, place the
piece of 2x4 as shown in the figure below.
FIGURE 66. BLOCKING THE ALTERNATOR FOR INSTALLATION
24. Install the brush block assembly (if required). Torque the mounting bolts to
2.3–3.2 Nm (20–28 in-lb).