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
140 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
TABLE 21. COMPRESSION TEST SPECIFICATIONS
Cylinder psi
Cylinder 1 >150
Cylinder 2 >150
For access to valve covers, refer to Section 5.4 on page 71.
Tools Required:
• General mechanical tools (metric and English socket set, etc.)
• Compression test kit
• LocTite Threadlocker Blue 242 or equal
• Torque wrench
• Valve cover gaskets (2). PN: A050X455
• Feeler gauge set
Compression Test Instructions:
1. Shut off the fuel supply to the generator set.
2. Place the generator set in Manual mode (disable standby and remote).
3. Open the generator set circuit breaker.
4. To test:
• Make sure the fuel supply is shut off to the generator set.
• Disable the ignition system by removing both spark plugs.
• Attach the compression tester to the spark plug hole.
• Crank the engine until a stable reading is achieved (approx. 20-30
seconds).
• Record the compression pressure.
• Check and adjust the valve clearance (see Section 5.4 on page 71).
5. Replace the valve covers using new gaskets.
6. Replace all of the other removed components.
7. Open the generator set fuel supply.
8. Test run the generator set for 5 minutes.
9. Close the generator set circuit breaker.
10. Enable Remote if desired.
11. Place the generator set in Standby mode if desired.