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Diesel Generator will not start

August 11, 2012, 10:43:28 pm

 
I have a 1999 320. It has the Powertech 10 kW generator with the Isuzu 3LD1 engine. It has 2268 Hours and was serviced recently with new oil, oil filter, fuel filter and air filter. It has been running fine since then.
   We are at about 10,000 feet in Colorado. Yesterday I ran it and it coughed some and put out a lot of smoke, but then after about 5 minutes it smoothed out and we ran it for about 3 hours. (I assumed due to altitude) Today I tried to start it. It will not start. The fuel pump clicks and I get one yellow light on the box-preheat, but engine does not turn over or start. I checked all visible hoses and seem tight and no leaks at the hoses, but I now see some either oil or diesel that appears to have dripped from the bottom of the engine. I have plenty of oil and fuel.
Any suggestions about what is wrong or what I could do?
Eric

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Re: Diesel Generator will not start

Reply #1 – August 11, 2012, 11:29:34 pm

I have the same generator which has had similar issues. My first system to check would be the air filter (even if has been changed recently) and secondly  the fuel filter  then the fuel pump.  Algae in the fuel can also cause these symptoms. My history with my Power Tech/Isuzu has been very frustrating until I found a Power Tech service center. If you reach the time that a professional is needed, I would not deal with anyone but a business that services generators exclusively(Power Tech). My experience ( $) even with the coach builder has not been positive.

                    Good Luck,
                        Josh

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Re: Diesel Generator will not start

Reply #2 – August 11, 2012, 11:39:29 pm

Eric,  If I read your note right, it sounds like an electrical issue, you say it will not turn over or start, well I wouuld be checking battery connections and the start switch's, both one on generator and the one on dash. 
Time to have a VOM and know how to use it, would make it simple to find where the problem is.
Also try using the boost switch in case one battery is too weak.
Cheers
Dave M

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Re: Diesel Generator will not start

Reply #3 – August 12, 2012, 06:53:53 am

I'm thinking electrical also.  The multi-pin connector behind the generator vibrates whenever the genny runs.  Over the years those connectors can get corroded or fail.  I'd pull the connector apart and clean it good first.  If that doesn't work then start checking wires, beginning with the starter.  I've bypassed the connector twice-once for the starter wire and once for the fuel pump shutdown solenoid.

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Re: Diesel Generator will not start

Reply #4 – August 12, 2012, 08:34:12 am

We have the same setup and suffered the same problem at high altitude. i.e. stumbled, coughed, smoked out the campground, wouldn't start. It was also cold out. I thought it was the glow plugs so I changed them with no improvement. I ended up cycling the glow plugs several times before allowing it to start and that did the trick. I would hold the dash switch until just before the starter kicked in. I'd do that four or five times and then vroom, it would work fine. When we got out of the high country, it went back to starting and running well. Good luck.
jor

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Re: Diesel Generator will not start

Reply #5 – August 12, 2012, 09:51:12 am

Critical symptom: "Engine does not turn over". That does not rule out a fuel problem or glow problem AS WELL, but if the engine won't turn over, neither fuel nor glow plugs come into play.

Start troubleshooting 12 VDC--check voltage at the starter lug static and while trying to crank.

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Re: Diesel Generator will not start

Reply #6 – August 12, 2012, 11:45:00 am

You didn't say how long you turned it over on the starter the day before. The manual usually gives how many seconds you can safely crank it without starter damage and how long you have to wait before trying again. Extended cranking can damage the starter or overheat the 12V cables that supply voltage to the starter. Would check cables for voltage like above post and also check the connections. Not sure if your starter solenoid is starter or remote mounted but is another place to check. High amp draw over an extended period can damage them.

A lot of smoke during and after starting is pretty normal at high elevations. The engine should smooth out within a minute. Any longer could mean an injector(s) with a bad spray pattern and also a contributing reason for leisurely starts. Five minutes to a smooth running engine is too long. Even after smoothing out, our generator does put out a barely visible amount of blue smoke and a bit of a foul smell over 8000 feet.

Starting at high altitudes can be difficult, especially on a cold morning. I glow the plugs several times before engaging the starter. If your main engine is warm, running it while attempting to start the cold generator works well. Higher voltage means faster cranking and less time for compression loss past the rings. Translates to higher combustion chamber pressure/temperature so the diesel fuel explodes easier.

How many hours on your generator? An intake valve(s) that is not fully seating can also make starting difficult. As the engine warms, the valve clearance may increase so it seats better and it runs better. Not usually a problem with the exhaust valve as the cold clearances are usually greater. Incorrect valve clearances not only effect starting but change the cam timing from the manufactures specs.

If this problem persists, have the generator checked for compression, glow plugs, injector opening pressures and spray patterns, valve clearances.

Pierce

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Re: Diesel Generator will not start

Reply #7 – August 12, 2012, 12:03:50 pm

One of the joys of trouble shooting from a non tech description such as "not turning over"  What does that mean in the real world?  Not rotating, not starting, not coming up to speed , not coming up to voltage or running ruff?
Have heard all of the above meanings to "not turning over".
Sure makes for alot of guessing  dont it.
SO, does the engine Rotate with the starter? What does rotate Mean ?  Is the starter making the engine do anything?
Maybe a little clearer question would reduce all the guessing options, Another reason I really do laugh so much. 
Thanks
Dave <

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Re: Diesel Generator will not start

Reply #8 – August 12, 2012, 12:49:43 pm

Thanks everyone. I got it started. I think problem was low voltage at the dash and generator. I will have to check that out. But this morning I cleaned the pins with Corrosion X. Also did starting batteries. Noticed that while starting batteries showed about 12.6 at terminal, at dash showed only about 11 volts or less.
I used boost switch and started right up (after a try or so) coughed and smoked for 5 minutes but ran and smoke went away. We are at 10386 feet and 40 degrees.
I will try and have all checked out when I get home, but for now running.
Thanks for the suggestions.
Eric

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Re: Diesel Generator will not start

Reply #9 – August 12, 2012, 01:40:33 pm

10.3K! No wonder you had problems. 7700 feet reduces chamber pressures by 25% and at your altitude, the pressures are down about a third. Very important to a compression ignition engine. You might try local fueling station diesel fuel as they may keep winter diesel in their tanks year around.

Low voltage readings at the dash indicate resistance somewhere or an inaccurate gauge. The terminal voltage is the important one.

Pierce

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