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
Table of Contents 10-2019
ii A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
5.3 Engine Oil ............................................................................................................................. 65
5.4 Engine Valve Clearance ....................................................................................................... 71
5.5 Normal Duty Air Cleaner Element Replacement .................................................................. 75
5.6 Exhaust System Maintenance .............................................................................................. 78
5.7 DC Electrical System ............................................................................................................ 79
5.8 Batteries................................................................................................................................ 79
5.9 Spark Plugs .......................................................................................................................... 83
5.10 Cleaning the Generator Set Housing.................................................................................. 83
5.11 Cleaning the Slip Rings ...................................................................................................... 83
5.12 Exercising the Generator Set ............................................................................................. 84
5.13 Complete System Test ...................................................................................................... 84
6. SERVICE...................................................................................................................................... 87
6.1 Control System ..................................................................................................................... 87
6.2 Fuel System .......................................................................................................................... 98
6.3 Cylinder Head Assembly Replacement .............................................................................. 105
6.4 Engine Exhaust................................................................................................................... 108
6.5 Alternator ............................................................................................................................ 109
6.6 Placing the Generator Set Back in Service ....................................................................... 129
6.7 Transfer Switch ................................................................................................................... 129
6.8 Line Circuit Breaker Troubleshooting ................................................................................. 129
7. TROUBLESHOOTING ............................................................................................................... 131
7.1 Troubleshooting Procedures............................................................................................... 131
7.2 Safety Considerations......................................................................................................... 131
7.3 GATRR Troubleshooting Approach .................................................................................... 132
7.4 Tools and Parts Required ................................................................................................... 133
7.5 Troubleshooting with the Local or Remote Displays ......................................................... 134
7.6 Utility-Powered Battery Charger Troubleshooting .............................................................. 134
7.7 Engine Flywheel Battery Charger Troubleshooting ............................................................ 137
7.8 Fuel Shutoff Solenoid Valve ............................................................................................... 139
7.9 Compression Test Procedure ............................................................................................. 139
7.10 Connecting with the InPower Service Tool ...................................................................... 141
7.11 Troubleshooting by Symptom ........................................................................................... 142
7.12 Troubleshooting with Fault Codes .................................................................................... 146
7.13 Remote Monitoring Communication Troubleshooting....................................................... 170
APPENDIX A. WIRING DIAGRAMS ............................................................................................... 177
A.0 Wiring Diagrams ................................................................................................................. 178