C44D5 Charging Alternator Issue

OES received shipment Cummins Middle East having C22D5 C33D5 and C44D5. Today our task is to perform the PDI and
off load startup of the gensets. We pick the complete available lot of C44D5 from shipment. During off-load test run we
observe that charging alternator not working or not charge the battery.

In our experience, it happens multiple time previously that new gensets charging alternator not working.

We perform some activity in our warehouse to make these charging alternator work. Complete working with pictures are
reference below. Genset which is under experiment have the following details.

Genset Model: C44D5 Genset Serial No: K16R213100

Engine Model: S3.8-G4 Engine Serial No: NTY842309
Alternator Model: Alternator Serial No:
Controller: Power Start 0500 Charging Alternator No: Lucas TVS 26021292
12V 40Amp

Original wiring of the system at the time of shipment.

When the system is energized on that wiring charging

alternator not producing its output and battery not charge. It is
verified in data logging via InPower. Results are mentioned in
Table 1.

Positive
WL
Negative
 Then we give additional battery negative to the installed
capacitor of charging alternator and check its behavior.

Problem is remains as charging alternator not producing output

voltage. Behavior recorded via InPower monitor log.
Mentioned in Table 2.

Extra negative
provided to
the alternator
capacitor.

As our field experience, we make the charging alternator work by making two types of modification in the system.

Modification # 01:
Remove negative from the AC point of
charging alternator and leave it as
open.

Remove
negative from
the AC point
Then start genset, now chagrining
alternator producing its output and
battery charging starts. Readings
mentioned in Table 3 which logged via
InPower option “Monitor”.
 Modification # 02:
Remove negative from the AC point of charging alternator and
connect it to the capacitor which found on the charging
alternator housing.

After this modification start genset, now chagrining alternator

producing its output and battery charging starts. Readings
mentioned in Table 4 which logged via InPower option
“Monitor”.

Both methods work normally as the genset tested half an hour

after both modifications one by one. No abnormality observed.

Remove negative from

the AC point and
connect it to capacitor

[Table 1,2,3,4 add here as their respective log]