5 Signs Your DG Set Needs Repair — Before It Fails During a Power Cut
Generators rarely fail without warning. In almost every emergency call we attend in Guwahati, the owner tells us afterwards that "it had been doing something odd for weeks". Here are the five signals worth acting on straight away.
1. It cranks longer than usual before starting
A healthy DG set fires within a couple of seconds. Extended cranking usually points to a weak battery, a clogged fuel filter, air in the fuel line, or failing glow plugs. Assam's humidity is hard on batteries — most need replacing sooner than the rated life.
2. Black, blue or white smoke from the exhaust
- Black: incomplete combustion — dirty air filter, faulty injectors, or overloading.
- Blue: the engine is burning lube oil — worn rings or valve seals.
- White: unburnt fuel or coolant entering the combustion chamber — stop and call an engineer.
3. Output drops or the set trips under load
If lights dim, motors struggle or the breaker trips when your usual load comes on, the cause could be an over-loaded set, a failing AVR, or a fuel supply that can't keep up. Don't keep resetting the breaker; each trip stresses the alternator.
4. New vibration or unusual noise
Knocking, rattling or a change in engine note means something mechanical is moving that shouldn't — loose mounts, a failing bearing, or injector timing drift. Vibration also loosens electrical connections inside the control panel, which is how small faults become expensive ones.
5. Leaks, corrosion or fluid loss between services
Oil, coolant or diesel pooling under the canopy is never normal. Rising humidity in Guwahati accelerates corrosion at terminals and hose clamps, so check the base of the canopy every month during monsoon.
What to do next
Note when the symptom appears — at start-up, under load, or continuously — and how the generator behaves. That detail lets our engineers arrive with the right parts the first time instead of diagnosing and returning.
Talk to Mecwel Engineers in Guwahati
We've been Assam's authorized Greaves Cotton dealer since 1991. Send us your requirement on WhatsApp and we'll reply with the right DG set, price and service plan — or call +91 97060-11988.