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
169A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
2. Measure the AC current and voltage while running the generator set with all
connected loads.
a. Identify faulty or short cycling loads.
b. Reduce loads as necessary. (The Cummins load management kit can be
used to automatically reduce connected loads.)
Code 61 - E-Stop Active
Logic:
Occurs when E-Stop switch is grounded. Once activated, it cannot be cleared
unless the switch is opened.
Possible Causes:
1. Activated local E-Stop button
2. Faulty connection or faulty E-Stop switch
Diagnosis and Repair:
1. Activated local E-Stop button
a. Reset the E-Stop:
i. Pull the E-Stop button out.
ii. Press the STOP button on the local display to clear the fault code.
2. Faulty connection or faulty E-Stop switch
a. Verify that the E-Stop button is working properly. The E-Stop button is a
closed contact when it is pulled out (not active) and an open contact when
pressed (active).
• Check for an open circuit condition in the connection and/or wiring
from the E-Stop control input (J1-16 input).
Code 76 - Alternator Over Temp
Logic: The temperature at the alternator is too high. The high temperature switch
opens between 197 - 209 °F (91.5 - 98.5 ° C). An open condition on this circuit
triggers the fault.
Possible Causes:
• Wire connections
• Faulty temperature switch
• Faulty generator set or fan drive
• Cooling air flow not adequate
Diagnosis & Solution:
1. Check the last fault recorded.
• If this fault has not been repaired, troubleshoot that fault.