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
149A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
12. Propane models only:
a. When ambient temperatures are less than 4.4 °C (40 ° F), the vapor
withdrawal propane tanks should be at least half full to provide proper
vaporization rate.
b. Propane that has more than 2.5% butane will not vaporize in ambient
temperatures at less than 0 °C (32 °F) so make sure to use HD-5 grade
propane.
c. Verify tank level and fuel line conditions.
13. Verify that the fuel solenoid valve is open.
14. Measure DC voltage at the fuel solenoid while the generator set is attempting to
start. Voltage must be greater than the threshold voltage of the solenoid (10.2
V). See the Fuel Shutoff Solenoid Troubleshooting section for more information.
• Repair wiring if necessary.
15. Check the generator set fuel lines and connections for leaks.
16. Remove the hose from the regulator and make sure air can pass through it.
17. Measure the fuel supply pressure at the generator set.
18. Check the governor actuator, actuator linkage, and throttle shaft for free smooth
motion without slop. Verify that the actuator is opening the throttle while
cranking.
19. Check the engine ignition system:
a. Verify that the spark plug leads are fully installed on the spark plugs.
Reconnect them if necessary.
b. Inspect the spark plug leads. Replace worn or damaged leads.
NOTICE
Spark plug leads are only available as part of the coil assembly.
c. Check the magneto output:
i. Using a spark tester, verify that the magneto coils are providing
acceptable output. If the output is not acceptable, verify proper
magneto gap (see Section 2.5 on page 17), and re-gap if necessary.
ii. Verify that the magnet that is in the flywheel is still magnetic, is not
damaged, and/or has not been misplaced. Replace the flywheel if
necessary.
iii. If the magneto coil is still not functioning properly, replace it.
d. Inspect the spark plugs for damage and proper gap:
• Remove and inspect spark plugs. If they are damaged or dirty, replace
them.
• Measure the spark plug gap. Re-gap if necessary.