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
170 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
2. Verify the generator set air inlet and air outlet panels are not obstructed. Verify
that there are no foreign objects within the enclosure that limit air flow.
3. Disconnect the generator set control P1 connector.
4. Verify that the P1 pin socket is fully inserted and inspect the pin socket
condition for corrosion and acceptable condition of contact wipers. To check
contact wipers, use one of the devices below:
• A mating pin connector
• A pin gauge the same size as the mating control connector pin (0.045 in)
• Any suitable device that will not damage the inside contact wipers of the
pin socket
If necessary:
• Clean, repair or replace the pin socket.
• Fully insert any partially inserted pin socket.
5. 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.
6. When reconnecting the harness plug to the connector, ensure that the pair are
fully seated next to each other.
7. Reconnect the P1 connector and test-run the generator set for fault occurrence.
8. Measure the temperature sensor wiring (P1-33 to GND) for continuity to ground.
Repair or replace as necessary. If the circuit is open, check the harness and
temperature switch for open conditions; repair or replace as necessary.
9. Visually inspect the generator set cooling fan for missing or damaged blades.
• Replace the fan if damaged in any way.
• The fan is connected to the rotor via a taper joint; verify that the fan is
securely connected to the rotor shaft.
◦ If the connection is loose, remove and inspect the tapers.
◦ If a component is damaged, replace the component.
7.13 Remote Monitoring Communication
Troubleshooting
Generator Set Connection Problems
Possible Causes:
1. The generator set is not connected to the Internet.
2. There are router and/or firewall problems.
3. The Connect Cloud is unavailable.
4. The control board software is not current.
5. There is a generator set control board problem.