Doosan G60-SIIIA troubleshooting: 3 fault codes and 116 symptom-cause-remedy entries from the manufacturer's own service documentation.
Doosan G60-SIIIA — full specs, parts & maintenance.
| Code | Meaning | Cause | Remedy |
|---|---|---|---|
| CAN ECU WARNING | CAN ECU WARNING | This indicates a fault condition detected by the engine ECU and transmitted to the DSE controller | |
| CAN ECU SHUTDOWN | CAN ECU SHUTDOWN | This indicates a fault condition detected by the engine ECU and transmitted to the DSE controller | |
| CAN DATA FAIL | CAN DATA FAIL | Indicates failure of the CAN data link to the engine ECU | Check all wiring and termination resistors (if required) |
| Symptom | Cause | Remedy |
|---|---|---|
| Engine cranks but will not start | Incorrect starting procedure | Verify correct starting procedure |
| Engine cranks but will not start | No fuel | Check fuel in tank and manual shut-off valve |
| Engine cranks but will not start | Exhaust restricted | Check and correct exhaust restriction |
| Engine cranks but will not start | Fuel filter plugged or full of water | Replace fuel filter or drain water from filter |
| Engine cranks but will not start | Injection pump not getting fuel or air in fuel system | Check fuel flow at supply pump or bleed fuel system |
| Engine cranks but will not start | Faulty injection pump or nozzles | Consult authorized diesel repair station for repair or replacement |
| Engine hard to start or will not start | Engine starting under load | Remove load |
| Engine hard to start or will not start | Improper starting procedure | Review starting procedure |
| Engine hard to start or will not start | No fuel | Check fuel tank |
| Engine hard to start or will not start | Air in fuel line | Bleed fuel line |
| Engine hard to start or will not start | Cold weather | Use cold weather starting aids |
| Engine hard to start or will not start | Slow starter speed | See "Starter Cranks Slowly" |
| Engine hard to start or will not start | Crankcase oil too heavy | Use oil of proper viscosity |
| Engine hard to start or will not start | Improper type of fuel | Consult fuel supplier; use proper type fuel for operating conditions |
| Engine hard to start or will not start | Water, dirt, or air in fuel system | Drain, flush fill and bleed system |
| Engine hard to start or will not start | Clogged fuel filter | Replace filter element |
| Engine hard to start or will not start | Dirty or faulty injection nozzles | Have authorized servicing dealer or engine distributor check injectors |
| Engine hard to start or will not start | Injection pump shut-off not reset | Turn key switch to "OFF" then to "ON" |
| Engine knocks | Low engine oil level | Add oil to engine crankcase |
| Engine knocks | Injection pump out of time | See your authorized servicing dealer or engine distributor |
| Engine knocks | Low coolant temperature | Remove and check thermostat |
| Engine knocks | Engine overheating | See "Engine Overheats" |
| Engine runs irregularly or stalls frequently | Low coolant temperature | Remove and check thermostat |
| Engine runs irregularly or stalls frequently | Clogged fuel filter | Replace fuel filter element |
| Engine runs irregularly or stalls frequently | Water, dirt, or air in fuel system | Drain, flush fill and bleed system |
| Engine runs irregularly or stalls frequently | Dirty or faulty injection nozzles | Have authorized servicing dealer or engine distributor check injectors |
| Below normal engine temperature | Defective thermostat | Remove and check thermostat |
| Below normal engine temperature | Defective temperature gauge or sender | Check gauge, sender, and connections |
| Lack of power | Engine overloaded | Reduce load |
| Lack of power | Intake air restriction | Service air cleaner |
| Lack of power | Clogged fuel filter | Replace filter elements |
| Lack of power | Improper type of fuel | Use proper fuel |
| Lack of power | Overheated engine | See "Engine Overheats" |
| Lack of power | Below normal engine temperature | Remove and check thermostat |
| Lack of power | Improper valve clearance | See your authorized servicing dealer or engine distributor |
| Unit is inoperative / Read/Write configuration does not operate | Check the battery and wiring to the unit; Check the DC supply; Check the DC fuse | |
| Unit shuts down | Check DC supply voltage is not above 35 Volts or below 9 Volts; Check the operating temperature is not above 70°C; Check the DC fuse | |
| Fail to Start is activated after pre-set number of attempts to start | Check wiring of fuel solenoid; Check fuel; Check battery supply; Check battery supply is present on the Fuel output of the module; Check the speed-sensing signal is present on the module's inputs; Refer to engine manual | |
| Continuous starting of generator when in the Auto Mode | Check that there is no signal present on the 'Remote Start' input; Check configured polarity is correct; Check the mains supply is available and within configured limits | |
| Generator fails to start on receipt of Remote Start signal | Check Start Delay timer has timed out; Check signal is on 'Remote Start' input; Confirm correct configuration of input is configured to be used as 'Remote Start'; Check that the oil pressure switch or sensor is indicating low oil pressure to the controller; Depending upon configuration, then set will not start if oil pressure is not low | |
| Pre-heat inoperative | Check wiring to engine heater plugs; Check battery supply; Check battery supply is present on the Pre-heat output of module; Check pre-heat configuration is correct | |
| Starter motor inoperative | Check wiring to starter solenoid; Check battery supply; Check battery supply is present on the Starter output of module; Ensure oil pressure switch or sensor is indicating the 'low oil pressure' state to the controller | |
| Engine runs but generator will not take load | Check Warm up timer has timed out; Ensure generator load inhibit signal is not present on the module inputs; Check connections to the switching device; Note that the set will not take load in manual mode unless there is an active load signal | |
| Incorrect reading on Engine gauges / Fail to stop alarm when engine is at rest | Check engine is operating correctly; Check that sensor is compatible with the module and that the module configuration is suited to the sensor | |
| Low oil Pressure fault operates after engine has fired | Check engine oil pressure; Check oil pressure switch/sensor and wiring; Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the module and is correctly configured | |
| High engine temperature fault operates after engine has fired | Check engine temperature; Check switch/sensor and wiring; Check configured polarity (if applicable) is correct (i.e. Normally Open or Normally Closed) or that sensor is compatible with the module | |
| Shutdown fault operates | Check relevant switch and wiring of fault indicated on LCD display; Check configuration of input | |
| Electrical Trip fault operates | Check relevant switch and wiring of fault indicated on LCD display; Check configuration of input | |
| Warning fault operates | Check relevant switch and wiring of fault indicated on LCD display; Check configuration of input | |
| Inaccurate generator measurements on controller display | Check that the CT primary, CT secondary and VT ratio settings are correct for the application; Check that the CTs are wired correctly with regards to the direction of current flow (pt, p2 and s1, s2) and additionally ensure that CTs are connected to the correct phase (errors will occur if CT1 is connected to phase 2); Remember to consider the power factor (kW = kVA x powerfactor); The controller is true RMS measuring so gives more accurate display when compared with an 'averaging' meter such as an analogue panel meter or some lower specified digital multimeters; Accuracy of the controller is better than 1% of full scale. Generator voltage full scale is 415V ph-N, accuracy is ±4,15V (1% of 415V) | |
| Module appears to 'revert' to an earlier configuration | When editing a configuration using the PC software it is vital that the configuration is first 'read' from the controller before editing it. This edited configuration must then be 'written' back to the controller for the changes to take effect; When editing a configuration using the fascia editor, be sure to press the Auto Mode button to save the change before | |
| Engine does not start — Starter does not turn | Battery discharged | |
| Engine does not start — Starter does not turn | Bad cable connections | |
| Engine does not start — Starter does not turn | Starter or starter switch failure | |
| Engine does not start — Starter does not turn | Safety relay failure | |
| Engine does not start — Starter turns but engine does not fire | No fuel injection | |
| Engine does not start — Starter turns but engine does not fire | No fuel in the fuel tank | |
| Engine does not start — Starter turns but engine does not fire | Clogged fuel filter element | |
| Engine does not start — Starter turns but engine does not fire | Air in the fuel system | |
| Engine does not start — Starter turns but engine does not fire | Control rack is stuck at no fuel position | |
| Engine does not start — Fuel is injected but engine does not fire | Incorrect preheating operation | |
| Engine does not start — Fuel is injected but engine does not fire | Faulty air heater | |
| Engine does not start — Fuel is injected but engine does not fire | Incorrect injection timing | |
| Engine does not start — Fuel is injected but engine does not fire | Low cylinder compression pressure | |
| Engine does not start — Engine fires but stalls immediately | Air in the fuel system | |
| Unstable engine running — Unstable low idling | Crack in injection pipe | |
| Unstable engine running — Unstable low idling | Injection nozzle failure | |
| Unstable engine running — Unstable low idling | Uneven compression pressure between cylinders | |
| Unstable engine running — Unstable low idling | Incorrect high idle speed adjustment | |
| Unstable engine running — Unstable low idling | Software/Electronic malfunction | |
| Unstable engine running — Engine hunting in medium speed range | Software/Electronic malfunction | |
| Unstable engine running — Engine malfunction in high speed range | Insufficient fuel supply | |
| Unstable engine running — Engine malfunction in high speed range | Air in the fuel system | |
| Unstable engine running — Engine malfunction in high speed range | Clogged fuel filter element | |
| Unstable engine running — Engine malfunction in high speed range | Piping failure (squeezed/restricted etc.) | |
| Unstable engine running — Engine malfunction in high speed range | Uneven fuel injection amount between cylinders | |
| Unstable engine running — Engine malfunction in high speed range | Incorrect valve clearance adjustment | |
| Unstable engine running — Engine malfunction in high speed range | Deteriorated valve spring | |
| Unstable engine running — Engine speed stuck at high idle | Engine control restriction or seizure | |
| Engine overheat — Cooling system defect | Insufficient coolant volume | |
| Engine overheat — Cooling system defect | Fan belt slippage | |
| Engine overheat — Cooling system defect | Thermostat malfunction | |
| Engine overheat — Cooling system defect | Radiator filler cap malfunction | |
| Engine overheat — Cooling system defect | Cooling system interior fouled | |
| Engine overheat — Cooling system defect | Radiator clogged | |
| Engine overheat — Improper servicing | Engine over-loaded | |
| Engine overheat — Improper servicing | Air cleaner element clogged | |
| Engine overheat — Improper servicing | Insufficient airflow/restriction | |
| Engine overheat — Improper servicing | Restricted coolant flow (high concentration of antifreeze, etc.) | |
| Low oil pressure — Lack of oil | Oil leakage | |
| High oil consumption — Wrong oil | Wrong type and viscosity | |
| High oil consumption — High coolant temperature | Over heat | |
| High oil consumption — Clogged filter and strainer | Clean and/or replace | |
| High oil consumption — Worn bearings and oil pump | Replace | |
| High oil consumption — Faulty relief valve | Replace | |
| Low engine output — Incorrect injection pump adjustment | Incorrect injection timing | |
| Low engine output — Incorrect injection pump adjustment | Too far advanced | |
| Low engine output — Incorrect injection pump adjustment | Too far retarded | |
| Low engine output — Injection nozzle malfunction | Incorrect injection pressure | |
| Low engine output — Injection nozzle malfunction | Incorrect spray condition | |
| Low engine output — Insufficient fuel supply to the injection pump | Lack of fuel in tank | |
| Low engine output — Insufficient fuel supply to the injection pump | Air in injection pump | |
| Low engine output — Insufficient fuel supply to the injection pump | Fuel filter clogged | |
| Low engine output — Insufficient fuel supply to the injection pump | Overflow valve malfunction | |
| Low engine output — Governor malfunction | Incorrect engine control adjustment | |
| Low engine output — Governor malfunction | Deteriorated governor spring | |
| Low engine output — Low cylinder compression pressure | Cylinder compression leakage | |
| Low engine output — Low cylinder compression pressure | Incorrect valve clearance adjustment | |
| Low engine output — Low cylinder compression pressure | Injector nozzle misalignment | |
| Low engine output — Low cylinder compression pressure | Cylinder bore wear | |
| Low engine output — Insufficient air intake volume | Air cleaner clogged | |
| Low engine output — Insufficient air intake volume | Restricted air flow | |
| Excessive oil consumption — Incorrect oil | Wrong selection of type and viscosity | |
| Excessive oil consumption — Incorrect oil | Too much oil quantity | |
| Excessive oil consumption — Engine burning oil | Faulty piston rings/damaged cylinder bores | |
| Excessive oil consumption — Engine burning oil | Faulty valve |
Fault codes and symptom→remedy steps extracted from this model’s service/owner documentation; verify against the official manual before servicing.
Documented causes: Engine starting under load; Improper starting procedure; No fuel; Air in fuel line. See the table for the matching fixes.
Documented causes: Engine overloaded; Intake air restriction; Clogged fuel filter; Improper type of fuel. See the table for the matching fixes.
Documented causes: Insufficient fuel supply; Air in the fuel system; Clogged fuel filter element; Piping failure (squeezed/restricted etc.). See the table for the matching fixes.