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
163A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
7. Inspect the condition of the P1 pin on the control board. If it is damaged or
severely corroded, clean or repair if possible, or replace the control board.
8. When reconnecting the harness plug to the connector, ensure that the pair are
fully seated next to each other.
9. Measure DC voltage at the starter during a start attempt.
a. Repair wire connections as necessary.
b. Replace the start solenoid and starter as necessary.
10. Check for air filter cleanliness.
• Replace the air filter as necessary.
11. Check for a blocked or damaged exhaust system.
• Repair or replace exhaust components as necessary.
12. Propane models only:
a. When ambient temperatures are less than 40 °F (34.4 °C), vapor
withdrawal propane tanks should be at least half full to provide the proper
vaporization rate.
b. Propane having more than 2.5% butane will not vaporize in ambient
temperatures at less than 32 °F (0 °C); use HD-5 grade propane.
c. Verify tank level and fuel line conditions.
13. Measure steady DC voltage at the fuel solenoid while the generator set is
running.
• Repair wiring as necessary.
14. Verify the vent hose is clear.
15. Check the generator set fuel lines for damage.
• Replace the fuel line as necessary.
16. Measure the fuel supply pressures.
17. 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.
18. 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.