High Fuel Consumption Causes of Cummins Diesel Generator Sets

Cummins diesel generators are known for their fuel efficiency, stability and durability. They are built to withstand heavy-duty and industrial applications. However, some users may encounter excessive fuel consumption when using Cummins generators. Here are some common reasons for high fuel consumption of Cummins gensets and tips on how to fix the problem.

Worn engine components

After being used for a long time, the engine components of Cummins diesel generator sets may be affected by wear and cause reduced performance. Generally, the wear and tear of cylinders, pistons and piston rings is more severe. Wear of these components can lead to reduced sealing performance, fuel leakage and inadequate combustion, which can increase the fuel consumption. In addition, turbocharger is a key component to improve the power and efficiency of the engine. If it malfunctions, it can also lead to insufficient intake pressure and inadequate fuel combustion, resulting in increased fuel consumption.

Problematic fuel system and cooling system

The function of the diesel fuel system is to inject a precise amount of atomized and pressurized fuel into each engine cylinder at the proper time. If there is something wrong with the fuel system, the fuel consumption is also affected. Blogged fuel filter and defective fuel injectors can lead to poor fuel supply or uneven fuel injection, which affects the full combustion of fuel. They are often blamed for increased fuel consumption in a diesel generator. In addition, the inaccurate fuel supply time is also an important reason for excessive fuel consumption.

Another likely cause of high fuel consumption in a diesel generator is a failing cooling system. As a matter of fact, your diesel generator can overheat and stop working due to a faulty cooling system. If the coolant temperature is too low or there is a leakage in the cooling system, the cooling effect of the engine will be affected, leading to the reduced fuel combustion efficiency.

Overload and harsh environments

The fuel consumption of Cummins diesel generators is also closely related to the load conditions and operating conditions. Overloading generator means that the engine works harder and needs to use more diesel fuel than usual. Running a generator at an excessive load not only causes extra fuel consumption, but also increases the operating costs, reduces the generator lifespan and cause increased emissions.

In addition, Cummins diesel generators operating in harsh environments such as high altitude, high temperature and high humidity can also affect the intake and heat dissipation effect of the engine, thereby increasing the fuel consumption.

No regular generator maintenance

Regular maintenance is essential to ensure the normal operation of diesel generators and reduce fuel consumption. However, some users may not realize the importance of generator maintenance when using the generators and don’t conduct routine maintenance tasks, resulting in serious residue and deposit build-up in the fuel system, too high oil level, blogged air filter and other problems. These issues can increase fuel consumption and affect engine performance.

How to reduce the fuel consumption of Cummins diesel generators?

To reduce the fuel consumption, keep in mind that you need to maintain and service your generator periodically. Check the fuel injectors from time to time and replace the faulty ones. Don't overload or under-load the generator. The carbon deposits will attach to several components, such as the injector, valve, and piston top. You need to get rid of them in time. In addition, keep the cooling system in good working order and properly control the load conditions and operating conditions. Using high quality engine oil and diesel fuel can also reduce the fuel consumption.

Dingbo Power is a professional diesel generator manufacturer in China with 18 years’ production experience. Feel free to contact us with any questions, concerns, or inquiries to learn more about the products & services we provide.