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
5. Maintenance10-2019
61A062J683 (Issue 1) Copyright © 2019 Cummins Inc.
To immobilize the generator set:
1. Press the generator set's red STOP button on the local display to stop the
generator set. Allow the generator set to thoroughly cool to the touch.
2. Thoroughly ventilate the generator set before disconnecting any leads.
3. Turn off and disconnect any AC powered devices at the generator set, such as
oil heater, battery heater, and battery charger before disconnecting the battery
cables.
4. De-energize and lock off any utility power to the generator set.
5. Turn off the fuel supply to the generator set.
6. Disconnect the negative (–) cable from the battery and secure it from
contacting the battery terminals to prevent accidental starting or electrical arcing
at the battery.
7. Place warning notices at each of the above locations that state, "Maintenance
in Progress – Immobilized for Safe Working."
Operating the Generator Set Cover Safely
To configure the local display or access the generator set, you will need to lift the
cover (lid). The cover of the generator set is designed to latch securely into the "up"
position to prevent accidental closure.
• To open: Lift the cover until the hinge pin drops into the hinge pin slot. Test
that the cover is secure by gently pressing down on the cover.
• To close: Lift up on the cover while pressing upward on the hinge pin and slide
the pin upwards out of the hinge pin slot. Carefully push the cover downward
and let go of the hinge pin allowing it to ride along the hinge until the cover is
closed.