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
82 A062J683 (Issue 1)Copyright © 2019 Cummins Inc.
Battery Maintenance
WARNING
Automated Machinery
Accidental or remote starting of the generator set can cause severe personal
injury or death. Arcing at battery terminals or in light switches or other
equipment, and flames or sparks can ignite battery gas causing severe
personal injury.
Always follow these procedures to avoid injury and/or damage:
• Ventilate the battery area before working on or near the battery.
• Wear safety glasses.
• Do not smoke.
• Switch a work light on or off away from the battery.
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.
4. Once work is complete, reconnect the negative (–) battery cable last.
Always:
• Keep the battery case and terminals clean and dry and the terminals tight.
• Remove battery cables with an insulated wrench or battery terminal puller.
• Make sure which terminal is positive (+) and which is negative (–) before
making battery connections, always removing the negative (–) cable first and
reconnecting it last to reduce arcing.
NOTICE
If the battery needs to be replaced, make sure that the replacement battery
specifications match those found in the Model Specifications in this manual.
Charging
Where generator sets are used infrequently and a consistent source of AC power is
not available, battery recharging must be put on a recharge schedule to ensure that
a fully charged condition is maintained.