MrClean has it right!! Blown head gasket is the most likely cause.

IMMEDIATELY CALL CUMMINGS.

I agree with posts#1,2 and 4.

You should totally disregard post #3.

head gasket, classic symptoms all others right except 3

check ventilation requirement of the engine one is air required for combustion, second your DG room ventilation to carry radiated heat from the engine .either situation of insufficient air for combustion and insufficient air to Carrie radiated heat from the engine( coupled with clogged radiator if yours is radiator cooled engine) will lead to high charge air temperature will lead to head gasket failure in my case it was turbocharger failure, we shifted the DG set to a new location meeting ventilation requirements as specified by cummins engine and solved the problem in any case call a cummins authorised dealer of your area good luck

crm

Thanks all for their replay.

Please clear it to me, head gasket problem means, is it about engine top head gasket or core cooler gasket?

What about no. 2 problem?

We are running with the problem-1 from last one month, no other symptom yet, cummins engineers visit several times, observe most of the parameters and replay "we can run the generator, but under regular observation". Our generator r/h: 1500(approximately) , we are far away from overhaul!

Please help us with clear suggestion.

thanks....

That rub. cummins engineer (basically he is a cool boy, not rubbish) already suggest us to calibrate the ECM system for fuel injection system, but the have not the facility in Bangladesh yet, so they just want to do top overhaul with injector & valve servicing.

My question is, did this servicing surely solve our problems?

Hi Bashir01219,

There's a lot of factors that I've experienced it before, such as;

1. Preventive maintenance to the engine itself, is the PM follow the recommendation from cummins, especially on prime engine power consumptions and/or usage is applicable to 200Hours, 150,000 Hours and so on until major overhaul took place.

2. Diesel quality and/or storage factors that will accumulated moisture into the systems.

Technically when the capability and/or efficiency of the engine drop, it will be back to preventive maintenance schedule, surely when high liquidity on the head side the pressure on the rocker arm will be more and this will create high exhaust side where we can visually seen the exhaust manifold temperature starting to raise tremendously.

We have experienced this since then with DEUTCH and IVECO prime engine in one of the island somewhere in Asia, we going back to the paper starting with;

1. Top overhaul.

2. Testing & commissioning with 120% 2 hours load test (inclusive of fuel injector testing).

3. Normal preventive maintenance, concentrating every 200hours replaced oil filter, fuel filter, moisture filter (water pressure separator filter), oil and lubricant change and vibration of the engine plank.

Thnks.

Thanks Mr. Khairul,

1. Our PM is quite good, we always use Cummins original spare parts and follow maintenance schedule as described in the manual.

2. Our DG performance is not bad at all, we can run the unit at 85% load without any abnormality (like oil pressure: 3.8-4.0 bar, radiator water temperature: 84-90 C, no abnormal sound, vibration)

3. Diesel quality & storage condition is good.

4. Pls. elaborate your no. 2 point, why exhaust manifold is too hot? DG fuel line is controlled by ECM, so did top overhaul with injector service is good enough for us?

Thanks again.

Thanks.

How head gasket blown is relating with problem-1, pls clear it.

Depending on where the head gasket is blown, oil can get in the coolant or coolant can get into the oil or both. Another thing can happen depending on where it is blown is heated combustion can get into the intake valve area or just the opposite. If coolant is getting into the cylinder it can cause more friction on the walls of the cylinder producing more heat. If it is blown into the coolant it can heat the coolant that's suppose to be cooling it and now it's just helping heat it up more. It's hard to explain but, with the information you have given I would say it is definitely the head gasket and that will make the engine run hot enough to make the exhaust glow.

Problem 2:The pressure of lube oil in the oil cooler is usualy higher than the pressure of cooling water,incase there is defective seal or cracked tubes in the cooler, oil will flow to water side but water will not flow to oil side. The reason is to avoid contamination of system oil i.e crankcase oil,thats why you didn't notice the trace of water in the lube oil line.