This manual will easily pay for itself on the first oil change, spark plug change, or air filter change that you perform! The manual includes pictures and easy to follow directions on what tools are needed and how the repair is performed.
Just imagine how much you can save by doing simple repairs yourself. Many people buy this manual just to have it around for when the inevitable happens. Sooner or later, maintenance will need to be performed. Be prepared for it when it happens by simply purchasing this service manual for later use! See below for a list of items that most of our manuals cover. Some manuals actually cover more items that are not even listed! Quick Links. Table of Contents.
Previous Page. Next Page. Page 4 8. Wear personal protective equipment such as safety glasses, protective gloves, hard hats, steel-toed boots, and protective clothing when working on equipment.
Page 8 Oily rags and other material can cause fire and restrict cooling. Keep the generator set, drip pan, and compartment clean. Keep the generator set clean and repair any oil leaks promptly.
However, employees or suppliers may be permitted to occasionally perform work on energized electrical equipment only when qualified and authorized to do so and when troubleshooting, or if de- energizing the equipment would create a greater risk or make the task impossible and all other alternatives have been exhausted.
Page Diesel Fuel Is Combustible Moving parts can catch on loose items such as clothing or jewelry. Do not wear loose clothing or jewelry near moving parts such as PTO power take-off shafts, fans, belts, and pulleys. Any questions regarding the installation or evaporative emission certification should be directed to Cummins Inc. Indicates a risk of personal injury from electrical shock or electrocution. Indicates a risk of personal injury from entanglement in moving parts. In line with Cummins Inc.
The users should therefore make sure that before commencing any work, they have the latest information available. This information is needed when contacting Cummins for parts, service, and product information.
Every character of the model number is significant. The last character of the model number is the specification letter which is important for obtaining the correct parts.
Page 18 2. Introduction This page is intentionally blank. Page 20 1. Page 22 When engine torques are not specified in Torque Specifications, tighten the screws and nuts according to the following tables.
The grade numbers are indicated on top of the screw or bolt head. Page 24 3. Page Special Tools Removing the Generator Set Some service procedures require removing the generator set from the vehicle. While there are many variations, generator set installations are generally classified as either conventional compartment mount or under floor mount. Page Disconnecting The Generator Set Some installations may require partial removal of the generator set to gain access to the battery cable, fuel line, and other connections.
Read this section before starting the removal. Disconnect the vehicle negative — battery cable at the battery terminal. Remove all mounting bolts. Slide the generator set out of the compartment onto the forklift.
Slowly lower the generator set before moving it to the service area. Page Reinstalling The Generator Set Note that the screws which secure the panels to the skid base are slightly longer then the screws between panels.
Keep the screws separate to make reassembly easier. Make sure that the shorter panel screws are used for the recovery tank. Page Installing The Housing Panels 1. Installation is the reverse of the removal. Use wire ties to secure the engine and AC harness to the left end panel. Tighten the panel screws according to torque specifications. It provides all the control, monitoring, and diagnostic functions required to operate the generator set control.
Page 36 4. Wait about 20 seconds for the amber status light to stop blinking and press the Stop switch to save the adjustment. Page Control-Inverter Removal 7. Lift the control-inverter housing out of the generator set. Make sure that the ground straps from the AC harness and skid base are reconnected and screws are tightened to Torque Specifications.
Going forward there will be one part number for the complete alternator assembly C. See the Table below. Page Stator Tests If the generator set is operational, drying the windings can be accomplished by running the generator set under full load for at least 1 hour.
Page Stator Removal Remove the 3 screws securing the inlet baffle assembly to the base. Remove the 2 screws that secure the inlet baffle assemble to the inner bulkhead and tilt it out. Page Rotor To prevent loss of magnetism due to shock, protect the rotor from being dropped or struck while the stator and rotor are removed. Keep metal chips away from the rotor. Remove the rotor. Mate the rotor to the crankshaft such that the middle line on the back of the flywheel lines up with the pointer in the flywheel housing.
Secure the rotor to the flywheel housing with 5 screws. Perform stator installation. Page 46 6. Disconnect the quick connectors going to the transformer and the lead at the starter housing. Remove the mounting screw and remove the battery charger. Battery Charger Installation Installation of the battery charger is the reverse of removal. Tighten all screws according to Torque Specifications. Page Battery Transformer Removal Disconnect the remaining quick connectors from the transformer.
Remove the 2 mounting screws. Remove the transformer. Battery Transformer Installation Installation of the transformer is the reverse of removal. Page Engine The blower pulls the air in from an opening in the bottom of the generator set to pressurize the engine compartment.
Air flows through the radiator from the top side of the muffler compartment and then out the bottom. Page Inspection 1. Remove the negative — battery cable from the battery to prevent accidental starting of the generator set during removal. Remove the 4 bolts which secure the pump pulley to its hub. Pull the pulley and belt off.
Governor The Governor is powered by the generator set control to position the fuel rack according to the load demand. Too large a droop results in objectionable voltage and frequency drops. Too small a droop results in hunting. The stop screw, rather than the fuel rack control lever, must stop the speed control linkage when the fuel rack is driven to the no fuel position to the right.
Loosen the locknuts on the 2 screws in the bottom row and remove the clamping screw. Adjust high-idle speed by turning the adjustment screw and set its locknut. Make sure the fuel rack return spring is in place on the rotor shaft to shut down the generator set if you lose hold. Page 62 4. Let the rotor go. The generator set should stop and display a fault code. Restart the generator set and check idle speed. Idle speed should be — rpm, readjust idle speed as needed.
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