I sent the following note and picture to the vendor I bough the generator from. Any ideas from the peanut gallery? I realize the text is kind of rough, but it is part of an ongoing conversation....
I've attached a picture with parts labeled.
I still don't have it running, so I'll explain.
Today:
First thing I did was fix the return plumbing on top of the injectors.
I did not end up replacing the injectors as when I got the new bolts it all sealed up.
The return line that goes from the right end of the injector string down to the filter was rubber and leaking so I replaced it with the new metal part
I got from you guys.
Between each step below I'm loosening the screws #B and pumping the little pump until I get clear fuel with no bubbles.
I'm treating screw B like one treats a brake bleed, you need to close it while clear fluid is coming out so it does not suck in air.
So after fixing that and priming and bleeding I try to run... nothing.
The I remove the left most injector line nut #A (shown removed in the picture)
when I crank no fuel comes out the empty fitting, nothing not even a drop.
Then I remove all four nuts, and nothing not even a drop from ANY of them.
I open cover #3 and lift up the plate and turn the motor over to make sure gear inside is turning. It is.
So one of the guys says diesel pumps have shear pins and that could be it.
So I remove panel #D and turn over the motor, you can see the plungers moving up and down so the shear pin is probably good.
At this point I text you.
So for the next step I remove the screws #2 and then unscrew the left most two fittings #1 and the one to the left of it.
Inside are little plungers and springs, the plungers may have been stuck but the are now free.
Then I reinstall the springs and plungers and turn the motor over (after bleeding) and noting comes out.
So I remove #1 again and manually operate the prime pump and fuel comes out.
If I only screw #1 in part way the prime pump can make fuel come out. IF I screw it in all the way the prime pump can't
make fuel come out. If I only put number 1 into the point that the prime pump can make fuel come out and crank the motor No fuel comes out.
A couple of comments
The Hose #10 is really stiff and too big for the nipple, I really can't keep it from leaking air.
All of the banjo fittings on the inlet side of the world seem to have non metalic seals that are dried out and leak.
These were some of the seals I asked you for, but I've removed #10 and the banjo fitting behind it and all the fittings going to the first fuel filter,
I've brought these home and I'm going to get new seals and new hose before I go back out.
Some questions:
So at this point I'm lost? The only thing I see that could be wrong is that the inlet check valve into the plunger pump assembly is stuck open?
At this point is seems like I'm down to a fairly simple concept" plunger pump and two check valves.
Where will I find the inlet check valves to unjam?
Can I remove the whole upper pump assembly #9, if so do I just remove the 4 nuts, or do I have to do something else?
#J is fixed and I'm guessing it should not be adjusted?
#H moves all the way counter clockwise when you try to start, I'm guessing that that is the ONLY shutoff the electronics has for the motor?
#C What is this and does it do anything?
It takes be 4 to 4 1/2 hours each way to go the the site.
I've now been to the site 4 times to work on the generator. not counting time on the phone at home or asking researching at home
I've spent close to 50 hours working on this what should I do next?
Did you guys actually run this motor at your office? (based on the way it was packed I'd guess no.)
So realize this motor has NEVER EVER EVER run, so what else could be wrong?
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