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. Service 10-2019
126 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
25. Connect the wiring harness lead to the terminal on the brush block holder.
Make sure to place the correct lead on the correct connector on the brush block
holder.
26. Install the brush block cover. Torque the fastener to 3.2–4.0 Nm (28–35 in-lb).
27. Reconnect AC accessory power wiring to terminal blocks TB-LINE and TB-
NEUTRAL, as well as round. Do not turn the power on for the AC accessory
power connections.
28. Install the top access panels.
29. Connect the battery charger (BC-P).
30. Reconnect the battery heater (if present) to the wiring harness.
31. Connect the display at plug P1.
32. Secure the wiring harness and alternator power leads to the clamps near the
top edge of the intake-side inner enclosure panel.
33. Install the alternator-end panel. Torque the bolts to 5.6–6.6 Nm (50–58 in-lb).
34. Install the crossbars and the hood assembly. Torque the bolts to 5.6–6.6 Nm
(50–58 in-lb).
35. Check the engine oil level. Add or drain oil as needed. Refer to the Model
Specifications section for the appropriate oil grade and weight.
36. Make sure that all bolts have been tightened to the correct torque value and all
wiring harness connections have been made.
37. Make sure all components have been installed correctly.
38. Make sure the wiring harness routing does not interfere with the moving parts
or contacts any sharp edges.
39. Install the battery and battery cables.
40. Install the intake and exhaust enclosure panels. Torque the bolts to 5.6–6.6 Nm
(50–58 in-lb).
41. Restore power to the AC accessories.
42. Turn the fuel supply on.
43. Open the generator set circuit breaker to prevent load transfer to the generator
set.
44. Start and run the generator set for at least one minute.
45. Stop the generator set. Troubleshoot any fault codes that appear.
46. Test system functionality by doing the following:
a. Close the generator set breaker.
b. Place the generator set in standby mode.
c. Open the main utility breaker connected to the transfer switch (if it is safe
to do so). The generator set will start, and the transfer switch will transfer
power to the generator set.