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. Troubleshooting10-2019
145A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
Possible Causes:
1. Marginal battery connections
2. Faulty battery
3. Charging system
4. Excessive cranking
5. Control electrical draw
Diagnosis and Repair:
1. Check the last fault recorded.
• If this fault has not been repaired, troubleshoot that fault.
2. Measure battery voltage at the battery and at the positive battery post on the
starter. If the voltage levels are not the same, go to the next step.
3. Inspect battery connections and cables for cleanliness, tightness, and damage.
• Clean, tighten, and repair connections and cables as necessary.
4. Check electrolyte level and hydrometer reading in maintenance type batteries.
• Replace electrolyte as necessary.
• Recharge or replace the battery as necessary.
5. Verify that the utility-powered battery charger is powered and check operation.
See the Utility-Powered Battery Charger Troubleshooting section.
6. Verify that the engine battery charger is functioning correctly. Measure battery
voltage and check for voltage increase while the generator set is running.
Starter Engages, Then Disengages
Logic: Cranking voltage dips below 8 VDC; microprocessor aborts start attempt
Possible Causes:
• Battery connections
• Faulty battery
• Charging system
Diagnosis and Repair:
1. Measure battery voltage at the battery and at the positive battery post on the
starter. If the voltage levels are not the same, go to the next step.
2. Inspect battery connections and cables for cleanliness, tightness, and damage.
• Clean, tighten, and repair connections and cables as necessary.
3. Check electrolyte level and hydrometer reading in maintenance type batteries.
• Replace electrolyte as necessary.
• Recharge or replace the battery as necessary.
4. Verify that the utility-powered battery charger is powered and check operation.
See the Engine Flywheel Battery Charger Troubleshooting section.