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
131A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
7 Troubleshooting
7.1 Troubleshooting Procedures
This section is a guide to help you evaluate problems with the generator set. You
can save time if you read through the entire manual ahead of time and understand
the system.
This section contains the following information:
• How to troubleshoot symptom-based problems that are not numbered
• How to troubleshoot numeric fault codes, including descriptions of warning and
shutdown code and corrective actions, such as checking fluid levels, control
reset functions, battery connections, etc.
Make sure the generator set is shut down and disabled before disconnecting or
connecting harness connectors to troubleshoot.
1. Press the generator set's "O" (Off) button to stop the generator set. Allow the
generator set to thoroughly cool to the touch.
2. If applicable, turn off and disconnect the battery charger from the AC source
before disconnecting the battery cables.
3. Disconnect the negative (–) cable from the battery and secure it from contacting
the battery terminals to prevent accidental starting.
NOTICE
It is recommended that all changes to settings be recorded at each site to
help troubleshoot the generator set.
NOTICE
Electrostatic discharge will damage circuit boards. Always wear a wrist strap
when handling circuit boards or when disconnecting or connecting harness
connectors.
7.2 Safety Considerations
WARNING
Hazardous Voltage
Contact with high voltages can cause severe electrical shock, burns, or
death.
Make sure that only personnel who are trained and qualified to work on this
equipment are allowed to operate the generator set and perform
maintenance on it.