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9-2013
9.Troubleshooting
8. Verifyclearventhose.
9. Runthegeneratorsetonshopfuelsupply;verifythetanklevelandfuellinecondition.
10. Checkthegeneratorsetfuellinesfordamage:replacethefuellinesasrequired.
11. Measureregulatorlockoffpressure.
12. Checktheintakemanifoldandgasketsforairleaks:tightenthefastenersandreplacethe
gasketsandmanifoldasnecessary.
13. Checkforablockedordamagedexhaustsystem:repairorreplaceexhaustcomponentsas
necessary.
14. Verify y actuator function by applying DCvoltage to theterminals: replace the actuator as
necessary.
15. Check k thecarburetorforbinding; inspectthe spring for dirt anddebris:clean the spring;
replacethecarburetorasnecessary.
16. Verify y thatthesparkplugcables are secureon the spark plugs: reconnect orreplace as
necessary.
17. Inspectignitionkilllead(J1-12)in n the harnessandatconnectorJ1: repairorreplace the
lead,terminal,orpinsasnecessary.
18. Measurethesparkpluggap:setthegaporreplacethesparkplugsasnecessary.
19. Verifyignitionsparkcondition.
20. Inspectthesparkplugleads,killleadterminalsatmagnetos,andmeasurethemagnetoair
gap:replacetheterminals,setthegap,orreplacethemagnetosasnecessary.
9.30 AlternatorOverTemp-FaultCode76
Logic:Temperatureatalternatoristoohigh(switchat170°F).
PossibleCauses:Wireconnections,faultytemperaturesensor,faultyDCfan,blockedintakeor
exhaustopenings
Diagnosis&Solution:
1. Verify y thatthe Last Fault is FC76: Yes, continuediagnosis;No, troubleshoot actuallast
fault.
2. Verify y the generatorsetenclosureisfullyclosedandlatched duringoperationtopromote
properairflow.
3. Verifythegeneratorsetenclosureforclearintakeandexhaustopenings.
4. Verifythetemperatureatthecustomerconnectionterminalblockwithinthegeneratorset.
5. DisconnectthegeneratorsetcontrolJ1connector,verifythattheJ1pinsarefullyinserted
andinspectpinconditionusingthestepsbelow:
• Usethetestpointsofthetestertool#420-0603
• Use e a a mating g pin connector, a pin n gauge of f the e same size (.045") ) as the mating
controlconnector pin, orany suitable devicethat willnot damagetheinsidecontact
wipersofthepinsocket
• Insert,repair,orreplacepinsasnecessary
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9.Troubleshooting
9-2013
6. Verifythetemperaturesensorresistance.Replaceasnecessary.
7. Measure e the temperature sensor wiring (J1-33) for r continuity. . Repair or replace as
necessary.
8. Visually y inspect the e alternator r fan for missing or damaged fins. . Replace e the fan if
necessary.
9.31 LowFuelPressure-FaultCode78
Logic:Controller sensedfuelpressureswitchopen and approachingfaultdeclaration:14,15,
22or36.
PossibleCauses:Wireconnections,fuelsystem,fuelpressureswitch,
Diagnosis&Solution:
1. Verify y thatthe Last Fault is FC78: Yes, continuediagnosis;No, troubleshoot actuallast
fault.
2. Verifythefuelsupplyandregulatorlockoffpressures.
3. Measure e steadyDCvoltageat the fuelsolenoidwhile thegeneratorsetis running; repair
wiringasnecessary.
4. Verifythefuellinesarenotkinkedorbroken/cracked.
5. Runthegeneratorsetonshopfuelsupply;verifythetanklevelandfuellinecondition.
6. Checkthegeneratorsetfuellinesfordamage:replacethefuellineasrequired.
7. Checkforfuelpressureswitchcontinuitytogroundwhilethegeneratorsetisrunning.
8. Checkforfuelpressureswitchcontinuityacrossitsterminalswhilefuelsystempressureis
applied.
9. Checkthefuelpressureswitchwiringforanopencircuit.
10. DisconnectthegeneratorsetcontrolJ1connector,verifythattheJ1pinsarefullyinserted
andinspectpinconditionusingthestepsbelow:
• Usethetestpointsofthetestertool#420-0603
• Use e a a mating g pin connector, a pin n gauge of f the e same size (.045") ) as the mating
controlconnector pin, orany suitable devicethat willnot damagetheinsidecontact
wipersofthepinsocket
• Insert,repair,orreplacepinsasnecessary.
9.32 FailureToTransferToGeneratorSet-FaultCode
79
NOTICE
Onlywith6634and6635(tobeperformedbyaCumminsTechnicianonly)
Onlywith6868and6869
Logic:Controllercommandedtransferswitchtostandbypositionbutstandbypositionfeedback
notreceivedafterthe5secondtransfertimedelay.
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9-2013
9.Troubleshooting
Possible Causes: Wire connections, , faulty y positional switch, , faulty y transfer switch
component(s)
Diagnosis&Solution:
1. VerifythatthemainACcircuitbreakerongeneratorsetisto“On".
2. Verify y thatthe Last Fault is FC79: Yes, continuediagnosis;No, troubleshoot actuallast
fault.
3. Manually start t an n exercise e session and d verify the transfer switch h position during g the
exercise.
4. Disablethegeneratorbyplacingthegeneratorlocalstartswitchinthe“Off"position.
5. Manuallyoperatethetransferswitchvialevertothegeneratorposition;checkforgenerator
positionswitchcontinuitytogroundatthetransferswitch.
6. Check for continuity y from m the e transfer terminal l block position n (TB4-6) to the generator
positionterminal(J2-5).
7. Checkforagroundsignalatthegeneratorpositionterminal(J2-5)atthecontrolconnector;
repairwiringasnecessary.
8. DisconnectthegeneratorsetcontrolJ1connector,verifythattheJ1pinsarefullyinserted
andinspectpinconditionusingthestepsbelow:
• Usethetestpointsofthetestertool#420-0603
• Usematingpinconnector,apingaugeofthesamesize(.045")asthematingcontrol
connectorpin,oranysuitabledevicethatwillnotdamagetheinsidecontactwipersof
thepinsocket
• Insert,repair,orreplacepinsasnecessary.
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9.Troubleshooting
9-2013
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10 CommunicationTroubleshooting
10.1 In-HomeNetworkAccesstoGeneratorSet
Troubleshooting
WARNING
Somegeneratorsetserviceprocedurespresenthazardsthatcanresultinseverepersonalinjury
ordeath.Onlytrainedandexperiencedservicepersonnelwithknowledgeoffuels,electricity,
andmachineryhazardsshouldperformgeneratorsetservice.
PossibleCauses:Badconnectionsorbadcommunications
CorrectiveActions:
1. Checkconnections.
a. VerifythattheEthernetcableispluggedintothegeneratorsetcontrolandtherouter.
b. Verifythatthecomputerthatisattemptingtoaccessthegeneratorsetisconnectedto
thesame routerasthegeneratorsetvia anEthernetcable(onthesamelocalarea
network).
c. Verifythatthewirelesscardonthecomputeristurnedoff.
d. Check k to o see if f both h ends of the Ethernet cable are assembled and crimped as
describedintheinstallationinstructions.Ifnot,reassembleandcrimpasdescribedin
theinstallationinstructions.
e. Verify thattheEthernet cable connections betweenthegeneratorsetandtherouter
aresolidandcorrect.
f. Proceedto"Checkcommunications."
2. Checkcommunications.
a. IftherouterisalsoconnectedtoanincomingconnectionfromanISP,checktoseeif
youcanaccessastandardwebpagewiththecomputerconnectedtothesamerouter
as the generator set. If not, contact your router r manufacturer r for troubleshooting
information.
b. ChecktoseeifthegreenandorangelightsareilluminatedattheEthernetconnection
portonthegeneratorsetcontrolboard.Ifthelightsarenotilluminated,thisindicates
that noinformation isbeingtransmittedorreceived. Testthecablebydisconnecting
theEthernetcablefromthegeneratorcontrolboardandconnectingittothecomputer
(swapthe cable with the exisiting Ethernet cable). With therouter connected to the
ISP,checktoseeifyoucanaccessastandardwebpage.
a. If you can access a standard web page, call l Cummins s Support at 1-800-888-
6626andselectoption1.
b. Ifyoucannotaccessastandardwebpage,gotothe“Check connections"step
above.
c. Check k toseeifthecorrectgeneratorIPaddresshasbeenentered.Ifnot,enterthe
correctIPaddressintheaddressbarofthewebbrowser.Besuretonotenter"www"
orothertextpriortotheIPaddress.
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10.CommunicationTroubleshooting
9-2013
d. Ifnoneoftheabovetroubleshootingtechniqueshelp,callCumminsSupportat1-800-
888-6626andselectoption1.
FIGURE60. NETWORKCONNECTIONS(CONTROLBOARDANDETHERNETCONNECTION)
10.2 RemoteInternetAccesstoGeneratorSet
Troubleshooting
WARNING
Somegeneratorsetserviceprocedurespresenthazardsthatcanresultinseverepersonalinjury
ordeath.Onlytrainedandexperiencedservicepersonnelwithknowledgeoffuels,electricity,
andmachineryhazardsshouldperformgeneratorsetservice.
PossibleCauses:Impropersetup,nohigh-speedinternetconnection,publicIPaddressisnot
activeorproperlysetup,incorrect IPaddress is entered, computerisconnectedto the same
routerornetworkasthegeneratorset,ortheinternetconnectionisfaulty.
CorrectiveActions:
1. Checktoseeifyouareabletoaccessthegeneratorsetwithyourin-homecomputer.
Ifnot,refertotheIn-HomeNetworkAccessTroubleshootingprocedures.
2. Verifythatyoufollowedthenetworksetupprocedures.
RefertotheNetworkSetupGuide.
3. Verifythatyouareusingahigh-speedinternetconnection.
4. VerifythatthepublicIPaddressisactiveandsetupproperlywiththeISP(InternetService
Provider).Ifnecessary,contacttheISPtoverifyyoursetup.*
5. Verify y that thecorrectpublicIPaddress isenteredinto the webbrowserof the computer
(i.e.xxx.xxx.xxx.xxx).
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10.CommunicationTroubleshooting
6. Verify y thatthecomputeris notconnectedtothesamerouterorlocalareanetworkasthe
generator set. If it is on the samenetwork, you willbe ableto access the generator set
usingthelocalnetworkIPaddressconfiguredonthegeneratorset.Thecomputerusedfor
internetaccessmustbeconnectedtoadifferentinternetconnectionthanthegeneratorset.
7. Checktoseeifyoucanaccessastandardwebpagefromacomputer.Ifnot,contactthe
ISPtotroubleshoottheinternetconnection.
8. Verifyallsettings,asdescribedintheNetworkSetupGuide.
9. If f theprevious stepsdonotcorrecttheproblem,contactacomputernetworkspecialistto
diagnose.
* To verify y your IP P address, access “whatismyipaddress.com" " from the browser of a
computerconnected tothe internet and onthe same network as thegeneratorset. This
webpagedisplaysyourcurrentIPaddresswhichshouldmatchtheIPaddressassignedto
youbyyourISP.
10.3 EmailAlertTroubleshooting
WARNING
SomeGeneratorSetserviceprocedurespresenthazardsthatcanresultinseverepersonalinjury
ordeath.Onlytrainedandexperiencedservicepersonnelwithknowledgeoffuels,electricity,
andmachineryhazardsshouldperformGeneratorSetservice.
PossibleCauses:Animpropersetup,thealertlevelisnotsetto“allevents,"emailscannotbe
received,theoutgoingemailaddressisnotincludedinyourcontactlist,theemailaccountisnot
capable of using g plain n SMTP P for the e outgoing g SMTP server r setup, , the e domain n name is s not
includedintheusernamefiledoftheNetworkSetupscreen,ortheDNS#1and#2valuesare
incorrectontheNetworkSetupscreen.
CorrectiveActions:
1. Check k to see if youareable toaccess the generator setwith yourin-home computer. If
not,refertoIn-HomeComputerAccessTroubleshooting.
2. Verifythatyoufollowedthenetworksetupinstructions.RefertotheNetworkSetupGuide.
3. VerifythatthealertlevelissettoAllEvents.
a. To verify that your generator set can send emails, selectDisable Standby and wait
severalminutestoverifythatyoudidreceiveanemail.
b. SelectEnableStandby and waitafewmoreminutesto verifythatyoudidreceivea
secondemail.
4. Sendanemailtothedestinationemailaddressandchecktoseeifyoureceivedthisemail.
If not, contact t your email service provider r or your ISP (Internet service provider) to
diagnose.
5. Checktoseeifthedestinationemailaccountshavespamfiltering.
a. Ifspamfilteringispresent,addtheoutgoingemailaddresstoyourcontactlist.
b. Ifspamfilteringisnotpresent,proceedtostep6.
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10.CommunicationTroubleshooting
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6. EnsurethattheSMTPserverinuseis s capableofdistributing nonSSLcertified emails.If
the SMTP server is s not capable e of sending non SSL certified d emails or the status is
unknown,pleasecontactyourISPtechnicalsupportforinformation.
7. VerifythatthedomainnameisincludedintheusernamefieldoftheNetworkSetupscreen
(i.e.username@domainname).**
8. VerifywithyourISPthattheStaticDNS(DomainNameServer)#1and#2arecorrect.
9. If f theprevious stepsdonotcorrecttheproblem,contactacomputernetworkspecialistto
diagnose.
** “No authentication" " is s possible e on some systems s by leaving the username and password
fieldsblank.
IMPORTANT NOTE: Changes are not saved unless s you u navigate through all three
NetworkSetupscreensandclickon“Done".Themessage“SettingsSavedSuccessfully"
isthendisplayed.
FIGURE61. NETWORKSETUP-PAGE1
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10.CommunicationTroubleshooting
FIGURE62. GENERATORSETHOMEPAGE
FIGURE63. NETWORKSETUP-PAGE2
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FIGURE64. NETWORKSETUP-PAGE3
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