TROUBLE SHOOTING DIESAL GENERATORS

Probable Cause & Solution

SNO

NATURE OF PROBLEM

ACTION TO BE TAKEN

A
A1
A2

FAILS TO CRANK
Low battery.
Bad battery connection.

A3

Blown fuse.

B
B1
B2

CRANKS SLOWLY
Low battery.
Bad battery connection.

B3
B4

Incorrect oil viscosity.

Load connected.

Check battery fl uid level.

Clean & tighten all battery & cable
connections.
Replace with recommended viscosity oil.
Disconnect load before starting.

C
C1
C2
C3
C4

CRANKS BUT WON'T START

Fuel below generator pickup level in tank.
Fuel supply shutoff valve closed.
Carbon deposits on spark plug(s).
Low oil level.

Add fuel.
Fully open fuel supply valve.
Remove spark plug(s) and replace.
Add oil.

D
D1
D2

EXHAUSTING BLACK SMOKE

Dirty air fi lter.
Choke stuck or misadjusted.

UNIT RUNS THEN STOPS WHILE

RUNNING
Low fuel level.
Low oil level.
Excess oil.

D1
D2
D3
E
E1

UNIT STARTS THEN STOPS WHEN

THE START SWITCH IS RELEASED
Low fl uid levels.

E2

Possible overheating.

ACTION
Check battery fl uid level.
Clean & tighten all battery & cable
connections.
Replace fuse on control panel.

Replace air fi lter.

Contact an Cummins Authorized Service O &
M

Add fuel.
Add oil.
Reduce engine oil level.

Check & bring all fl uids up to the appropriate

levels.
Check for blocked air fl ow or other possible
causes of over heating

E3
E4

Other functional problem.

No AC output.

F
F1

UNIT RUNS THEN SURGES

Loose or worn spark plug leads.

F2

Defective ignition coil, wiring, or control

components
Governor out of adjustment.
Combustion air pre-heat malfunction
Oil filters chocked

F3
F4
F5
G

CIRCUIT BREAKER
Trips

DG COMMON FAULTS

H1

Battery low voltage (cells damage)

H2

Contact Authorized Dealer O & M

Contact Authorized Dealer O & M

Check plug leads AT ignition coil. Contact an

Cummins Authorized Dealer O & M
Remove clean or replace.
Contact Authorized Dealer O & M
Contact Authorized Dealer O & M
Remove clean or replace.

Overloaded circuit. 1. Turn-off some of the

electrical load, and reset the circuit breaker.
To check the bridge rectifier of the charger

Improper charging

To check the Float /boost mode of the charger.

H3

Fuel line air lock

H4

Filter choke/No fuel in tank/ valves are closed

H5

Low common rail preassure

Remove the air lock

Replace the filter /Fill the tank up to level/ open the
valves.
Replace the filter or fill the tank up to the level & fuel
pump to be check

Fuel injectors defective

Injector calibration to be done or replace

Water seprator choke

Filter to be replace.

Self starter defective

Starter to be repair/ replace

Self starter saloniod defective

To be repalace the saloniod

Fuel filling solonid fault

To be repair /replace the solonoid

Fuel level senors fault

To be replace the sensors

Turbo charger implier damage

Specified impeller to be replace

Turbo charger bearings /bushes damage

To be replace the bearings/bushes

Radiator fills damage

Adjust the fills, if nessary replace.

Radiator fan motor defective (for D.G.-1 only)

To be replace / replace the motor.

H6
H7
H8
H9
H10
H11
H12
H13
H14
H15
J
J1
J2
J3
J4
J5
J6
J7

DG HUNTING
Filter choke

Filter to be replace.

Dust particals in the fuel tank/line

Clean the tank/Line

Sensors loose connection

To be tighten the connections.

Radiotor belt damage

To replace the belts

Air Filter chocked

To be clean the filter

Lack of coolent

Fill the coolent

Coolent pump defective

Pump to be repaired & replaced

J8
J9
J10
J11
J12
K
K1
K2
K3
K4
K5
L
L1
L2
L3
L4
M
M1
M2
M3
M4
M5
M6
M7

Low oil level

To fill the oil up to the level

Radiotor fan damage

Replace

Oil leakage

o' Ring to be replaced

Radiotor choke

Clean the raditor

Exhaust smoke leakage

Repair

BATTERY NOT CHARGING

Battery sulpher formation

Clean the terminals and apply the petroleum jelly

Dynamo defective

To be repair/replace

Dynomo belt damage

Replace the belt

Charger failure

To check the charger

Terminals loose contact

Trminals to be tightened /Lugsto crimp properly

POOR OIL PRESSURE

Low oil level in sump

To fill the oil up to level

Oil pump defective

To be repaired/replace

Lub oil filter chocked

To be replaced

Lub oil pump sterner defective

To be replaced

LEAKAGES
Cylinder head gas cut damage

Gasket to be replace

Oil sump gas cut damage

Gasket to be replace

Turbo charger hose oil leakage

Hose to be replace

Fly wheel seal damage

Seal to be replace

Engine block dummy seals damage

Specified seal to be replace

Radiator tube damage

Repair the radiotor tubes

fuel hoses damage

Specified fuel hases to to be replace

SIMPLE DG BLOCK DIAGRAM

SIMPLE DG

SIMPLE DG BLOCK DIAGRAM