Generator suddenly stopped

[richard5933]

Our diesel generator has been working well for a while. The Perkins had done oil seals replaced but otherwise had been a strong runner. Also had the lift pump replaced while the unit was out for service as a preventative step, and the injector pump was rebuilt.

While running this morning it sputtered a bit and then cut out. Sounded like it ran out of fuel.

I've got 100 gallons of fuel, and the electric pump bringing the fuel from the tank is making its usually sounds when turned on. The engine cranks well and will build oil pressure while cranking.

My initial guess is that I've got a fuel line block, or a problem with the electric pump.

Before I start tearing things apart I wanted to see if anyone has any suggestions on where to look.

Any thoughts?

Richard

1964 PD4106-2412

[lostagain]

Maybe it just over heated and shut itself off. It would restart once cooled off. Otherwise, is there a fuel filter that might be plugged?

JC

[richard5933]

Maybe it just over heated and shut itself off. It would restart once cooled off. Otherwise, is there a fuel filter that might be plugged?

JC

Definitely not overheated. That was the first thing I checked. If there is a filter, I haven't found it yet. I know, that's something to remedy once we get the engine running again.

1964 PD4106-2412

[Zephod]

Disconnect the fuel line after the fuel pump and see if it pumps fuel.


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[brmax]

Can you or have you tried starting it outside. Just wondering if the fuel solenoid is being pulled back, in the normal start order.  It maybe one or other of these switches that are preventing the operation, they do fail never at the right time.  Looking like an oil pressure sender sw. Allthough Not the gauge switch as many are seperate. Also the coolant temp sw again not always the the gauge sender switch. So in this rough guesstimate sometimes these switches mentioned are wired to a small box relay doing the tough work. Where the signal wire say if engine is hot the signal just breaks and the relay does its job disconnecting main power leads.

Floyd

[richard5933]

I ran into another bus nut up here in Northern Wisconsin, and I think we may have found the problem.

I pulled the Webasto out last week to send in for repair. To keep the fuel from leaking I connected the two fuel lines together.

Seems that the generator and Webasto both share the same fuel feed from the tank, and my guess is that by shunting the lines I created a way for the generator to suck air.

I plugged both lines at the Webasto location. Still can't get the generator to start. When I get somewhere where it's possible I will crack the line between the electric fuel pump and the generator. My hope is that I will be able to bleed the air from the line.

Richard

1964 PD4106-2412

[chessie4905]

If it has an electric fuel pump, pull the hose off the output going to the injection pump, add a piece of hose and turn on the electric pump to see if it flows fuel. If it still has the mechanical pump and electric, bypass the mechanical pump to check. Either way don't use the mechanical pump any more. We stopped using ours on our 12 kw Kohler/ Perkins years ago. Too much cranking if it runs out of fuel and NOBODY is going to have a replacement out in nowhere. There should be a cartridge fuel filter mounted on the side of the engine, at least ours has one. If no fuel filter, you need one before electric fuel pump.In fact, electric fuel pump mfgrs have this requirement in their directions. Are you pulling fuel from your main tank? Did you run fuel low?

[bigred]

Any time a diesel engine just quits for no reason at all I check the shut down solenoid !!!

[akroyaleagle]

In the control box should be some 1" square relays. Change position with them and try again.
If it continues to run, you've found the problem.

[Dave5Cs]

Ours shuts down at 1/2 a tank so you don't run the engine out of fuel. While on the road especially in the heat and ac running we fill up at 1/2 tank to keep the jenny going. You can find out by using a fuel can and take the feed hose off and put it in the can and try starting it to see if it is out of fuel.

[richard5933]

Any time a diesel engine just quits for no reason at all I check the shut down solenoid !!!

No shut down solenoid, just a governor that keeps the fuel flowing. It is functioning properly.

1964 PD4106-2412

[richard5933]

Ours shuts down at 1/2 a tank so you don't run the engine out of fuel. While on the road especially in the heat and ac running we fill up at 1/2 tank to keep the jenny going. You can find out by using a fuel can and take the feed hose off and put it in the can and try starting it to see if it is out of fuel.

We're sitting at just over half a tank. If my memory is correct, we've run the generator with less fuel before with no problem. But, we're planning to fill tomorrow and I'll be tickled if that solves the problem. If not, I'm leaning towards a clogged fuel filter.

I did confirm that there is a filter mounted on the back of the engine.

When I took our the Webasto the fuel in our was brown and smelled off. If that got sucked into the filter for the generator then it would not be surprising if caused problems.

Richard

1964 PD4106-2412

[richard5933]

In the control box should be some 1" square relays. Change position with them and try again.
If it continues to run, you've found the problem.

The control box is not the original. No relays other than the Murphy Switch. I kept it simple after we replaced the generator head and had to rebuild the engine controls / failsafe system.

1964 PD4106-2412

[richard5933]

Just filled tank. No luck. I'll try new filter when we get home.

1964 PD4106-2412

[richard5933]

Got this solved finally.

Here's what happened. Shortly before the problem I pulled the Webasto to send it for service. When doing so, I connected the fuel supply & return together to eliminate drips & leaks. Didn't know that the generator was sucking fuel from the same straw as they are connected just before going into the tank. When i fired the generator it sucked the remaining fuel from the Webasto lines, ingested lots of dirty fuel, and then started sucking air since the return line was now part of the loop and the fuel level in the tank was below the level of the return line.

I thought I'd fixed the problem when i separated the two lines from the Webasto and plugged them individually. I've got an electric fuel pump before the mechanical one which is supposed to reprime the system after such events. What I didn't know is that the injector pump on the Perkins has a habit of holding air pockets inside it. Apparently it was necessary to crack the lines into and from the injector pump while running the electric pump until all the air cleared.

Lesson learned.

Actually, two lessons learned, as I managed to make it three days & nights operating on my battery bank alone and no generator. Great forced lesson in power management. Fortunately the weather was pleasant for sleeping and the little driving we did during the day was enough to give a charge to the house batteries. Sure glad that I put the solenoid to bridge the house batteries with the chassis batteries so they charge while driving. Also thrilled that I had the forethought to take along a small propane burner and a few 1 lb cans of propane. Gotta have hot water for coffee. The only thing I wasn't able to get was a warm shower, as the water heater is 120v only.

Next spring we're planning to add 960 watts of solar to the roof.

Richard