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
7. Troubleshooting 10-2019
134 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
• Alternator and engine removal and installation:
◦ Tools:
▪ Piece of standard 2 x 4 lumber cut to 4 in
▪ Socket or similar tool less than 18.6 mm (0.73 in) in diameter
▪ Wheel/gear puller
▪ Rotor removal tool
◦ Parts:
▪ Nut (M12 x 1.75)
▪ Bolt (M14 x 2.0)
▪ Intake manifold gaskets (4)
▪ Throttle body to airbox gasket
▪ Throttle body to intake manifold gasket
▪ Exhaust manifold gaskets (2)
▪ Engine oil (see the Model Specifications section)
7.5 Troubleshooting with the Local or Remote
Displays
If a fault shutdown occurs, the FAULT light on the local or remote display will come
on and the screen will display a description of the fault, the fault code number, and
the total hours of generator set running time when the fault occurred.
The shutdown codes are listed below in numerical order along with step-by-step
corrective actions.
The SERVICE light on the local or remote display will come on only to notify the
homeowner of the following:
• A required maintenance interval,
• If a low oil level is detected, or
• If low battery voltage is detected
7.6 Utility-Powered Battery Charger
Troubleshooting
WARNING
Combustible Gases
Batteries can explode, causing severe skin and eye burns, and can release
toxic electrolytes.
Do not dispose of the battery in a fire, because it is capable of exploding. Do
not open or mutilate the battery.