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. Maintenance 10-2019
64 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
WARNING
Automatic startup of the generator set can cause severe personal injury or
death. Make sure the generator set is shut down and disabled:
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. Turn off and disconnect the battery charger from the AC source before
disconnecting the battery cables.
3. Disconnect the negative (–) cable from the battery and secure it from
contacting the battery terminals to prevent accidental starting.
NOTICE
Perform all service at the time period indicated, or after the number of
operating hours indicated, whichever comes first.
TABLE 11. MAINTENANCE FREQUENCY
Maintenance Task
Maintenance Frequency
First 25
Hours
and 100
Hours
Every 24
Hours
Every 24
Hours or
6 Months
Every 200
Hours
Every 2
Years
Check Engine Oil Level ■
2, 3
Change Engine Oil and Oil Filter ■ ■
4
■
4
Adjust Engine Valve Clearance ■
1, 6
■
1, 6
Replace Engine Air Filter ■
4
■
4
Clean and Check Starting
Battery
■
Clean Slip Rings ■
7
Complete System Test ■
5, 6
■
5, 6
1. Perform sooner if engine performance deteriorates.
2. Perform more often when operating in high temperature conditions.
3. Check daily during power outages, or monthly without power outages.
4. Perform more often when operating in dusty conditions.
5. See the automatic transfer switch manual for testing of load transfer.
6. Must be performed by a qualified service technician (authorized Cummins Inc. service
provider).
7. Clean slip rings with an approved tool, 3M Scotch Bright pads Maroon (Grit Equiv. 360-
400) OR 3M Three-M-ite 400 grit cloth.