Generator Issues AGAIN!

Topic: Generator Issues AGAIN! (Read 1553 times) previous topic - next topic

Generator Issues AGAIN!

March 19, 2012, 11:30:03 am

Well, I can say that my generator ran fine for our entire Spring Break trip (probably a good 24 hrs during travel time and an overnight stay in WalMart) up until the last 5 minutes of our trip. Then it died. I could restart but it coughs and sputters for about 30 seconds then evens out as normal, then dies again. I waited a good 30 minutes before the next try and it ran for at least 15 minutes. I left it on with both air conditioners on at 2 am in storage and went home to sleep hoping it would be running in the morning. Ran out 6 hours later and it was dead again. I'm HOPING it's fuel related this time as what I did before on this thread (PowerTech 10KW Runs then Stops) seemed to have fixed the previous issues. Symptoms are definitely different. The fuel filter is relatively new, changed less than probably 30 hours ago. Time to inspect the fuel lines when I get a chance. I wish my generator had some fault code lights or something. I hate these shooting in the dark issues. You can throw a lot of time and money at something like this and be totally off the mark.

Re: Generator Issues AGAIN!

Reply #1 – March 19, 2012, 11:43:35 am

Benjie, This may be a long shot. I have the same Generator.
In 100+ heat in AZ a few years ago I had the same symptoms, run 15 minutes, stop, easy start again shut down.
I found in the control box at the back of the box some wires attached with ring ends to a board. One of the wires looked like it was sound but with a slight wiggle the generator stopped. I replaced the wire end and tightened up all of them and have had no problem since. Apparently the ring end on the wire was improperly crimped or the wire wiggled loose.
Hope you find the cause.
Gary B

Re: Generator Issues AGAIN!

Reply #2 – March 19, 2012, 11:51:07 am

Thanks Gary. The symptoms sound more like fuel delivery issues to me given the sputtering going on at start up after it dies, but I'm open to all suggestions. My first action is to try running out of a bucket. Hopefully that fixes the issue. If not, then it'll be off to other possible issues such as electrical, etc.

Re: Generator Issues AGAIN!

Reply #3 – March 19, 2012, 12:22:05 pm

Being over 15 years old, I would be having a real good look at the fuel lines between the tank and the generator including the fuel filter, both supply and return lines. Second would be a fuel filter that is full of crap, they will act the same way. Also if you can run it with no load for awhile with no issues, that only appear when you add load such as two a/c units etc. sure indicate fuel starvation, IE dirty fuel filter, just because it has been about 30 hours means little if you have algee or other crap in the fuel system.
Cheers
Dave M

Re: Generator Issues AGAIN!

Reply #4 – March 19, 2012, 12:49:55 pm

Dave,

Excellent advice! I'm curious, how long is OK to run the gen with a light load. I read somewhere that it can be bad to run for extended periods of time with light loads?

Best Regards,
Benjie

Benjie Zeller
(512) 587-4628

Re: Generator Issues AGAIN!

Reply #5 – March 19, 2012, 01:20:36 pm

Benjie,

You are correct, that you don't want to rack up a lot of hours at light loads. Kind of like starting your car and leaving it run in the driveway day after day.

But, I think Dave was suggesting that as a way to determine if the fuel filter was clogged. Fuel demand under light load is less than at heavy load. If it runs at light load, but stumbles and dies under heavy load, it would be another indicator that you might have inadequate fuel flow. Sure, it could be other things, but look at the inexpensive easy ones first.

Brett

Re: Generator Issues AGAIN!

Reply #6 – March 19, 2012, 01:55:56 pm

Brett,

Thanks. I guess what I was asking is an hour or two OK? Up to this point, I haven't let it run for more than 10 minutes without at least one AC or fan on.

Benjie

Re: Generator Issues AGAIN!

Reply #7 – March 19, 2012, 01:59:12 pm

One hour at light throttle will create no long-term issues and is a good indicator of fuel flow.

Have you had a chance to visually inspect the generator fuel filter. Actually, changing it would be a low cost good starting place.

Re: Generator Issues AGAIN!

Reply #8 – March 19, 2012, 02:04:18 pm

No, I haven't. This all occurred at 2 am last night as we arrived home. Will try to tackle it sometime in the next week.

Re: Generator Issues AGAIN!

Reply #9 – March 19, 2012, 02:24:49 pm

Be sure to ck the inline fuel filter next to the small electric pump. This one seems to get overlooked and it could have the original on it which is painted same as gen. It is hard to see. Good Luck DAN

Re: Generator Issues AGAIN!

Reply #10 – March 19, 2012, 02:25:48 pm

Assuming your generator is in average condition, running with no or very light load for 8-10 hours will not hurt it in any way, such as runnng at night with the a/c on and during the night it gets cold and the load drops off to a near zero load until you get up and fix chow. No panic.
Dave M

Re: Generator Issues AGAIN!

Reply #11 – March 19, 2012, 02:27:03 pm

Uhhh, there are two? If so, I'm fairly certain it wasn't changed.

Best Regards,
Benjie

Benjie Zeller
(512) 587-4628

Re: Generator Issues AGAIN!

Reply #12 – March 19, 2012, 02:41:35 pm

1993-1995_powertech_10kw-belts-filters-hoses-for-foretravel

This only shows one filter?

Best Regards,
Benjie

Benjie Zeller
(512) 587-4628

Re: Generator Issues AGAIN!

Reply #13 – March 19, 2012, 02:41:43 pm

Sorry for all the questions. How would one inspect the filter for algae? Remove and cut it open? I assume looking for something greenish?

Best Regards,
Benjie

Benjie Zeller
(512) 587-4628

Re: Generator Issues AGAIN!

Reply #14 – March 19, 2012, 02:47:05 pm

Yes, there is an inline filter, always over looked but allows the engine to start sputter then die. Check to see how much fuel you are getting to the large filter. DAN

Re: Generator Issues AGAIN!

Reply #15 – March 19, 2012, 02:48:26 pm

Algee is a black slime

Dave M

Re: Generator Issues AGAIN!

Reply #16 – March 19, 2012, 03:16:23 pm

I have had this black slime on a diesel engine car that did not cover the entire filter. It would idle all day, but when you drove it 60, it would die, and would not immediately restart but always would after it had sat for a short while. Additionally, there may be a second filter change right away as there may still be some algae/slime in the tank that will gum up the new filter. If the problem is rectified with a new filter, you may wish to purchase a second in the event that you need that second one on short order. Changing them is really not a big deal.

Re: Generator Issues AGAIN!

Reply #17 – March 19, 2012, 03:57:00 pm

Add Algaecide to your deisel, but be ready to change your filter if you have a lot and it breaks it loose.
I add some about 2000 miles before I go in for service. Dan

Re: Generator Issues AGAIN!

Reply #18 – March 19, 2012, 05:30:09 pm

Quote from: drcscruggs – March 19, 2012, 03:16:23 pm

I have had this black slime on a diesel engine car that did not cover the entire filter. It would idle all day, but when you drove it 60, it would die, and would not immediately restart but always would after it had sat for a short while. Additionally, there may be a second filter change right away as there may still be some algae/slime in the tank that will gum up the new filter. If the problem is rectified with a new filter, you may wish to purchase a second in the event that you need that second one on short order. Changing them is really not a big deal.

Most diesel cars have a tank drain. After the light comes on, just drain and rinse the tank. The assembly where all the hoses come out at the bottom of the tank is removable. Pull the sending unit for the fuel gauge at the same time and clean it. Good to clean the contacts also. Algae on the sliding fuel sender contact is the biggest reason for intermittent fuel gauge readings.

Be sure to change both the spin-on bigger secondary filter as well as the small plastic primary filter. Good idea to change the secondary on a regular basis at any water that sits on the bottom will rust a hole in the bottom of the filter. Have had this happen several times.

Lack of tank drains was another problem that Olds had when they decided to install a diesel engine. Once the tank had algae, they had to install a new one. Dealers replaced a lot of Volvo tanks also when they put the diesel VW van engine in them.

Pierce

Re: Generator Issues AGAIN!

Reply #19 – March 19, 2012, 06:37:07 pm

I have a 96u270 and two years ago I had the same thing happen to me...I found the fuel pump was weak and replaced...Short time later it did the samething again.
This time I found small cracks in the fuel line coming out of the main diesel tk...The small cracks allowed air to mix with the diesel and this is what caused my stalling issues.. Replaced all four lines,two to main drive engine and the two to the gen...This fixed all issues for me,Hope this helps

Re: Generator Issues AGAIN!

Reply #20 – March 19, 2012, 06:53:22 pm

Yes, cracked fuel lines are reasonably common in 10+ year old applications. And, as you say, there is often no outward sign of failure, since they suck air in, not let fuel out.

Re: Generator Issues AGAIN!

Reply #21 – March 19, 2012, 07:09:02 pm

I went by today to change the large filter. Now, I can't seem to get any fuel to the filter or engine? How do you prime the system? I thought you pushed down on the STOP PREHEAT button in Picture 1 and loosened the bolt where my finger is pointing in Picture 2. I seem to remember a clicking sound when pushing STOP PREHEAT before (thought that was the fuel pump), but that's not happening. I'm wondering if the fuel pump might be bad? I've held the STOP PREHEAT button down for approximately 20 seconds, removed the fuel filter, bone dry. I also cycled the engine with the START button for probably 20 seconds, fuel filter again bone dry.

Picture 3 is of the small fuel filter. It fell out when I removed the bottom cap. Anyone know if in the pic we're looking through the top towards the bottom or bottom towards the top?

The fuel lines actually look pretty good, like someone may have replaced them in the past. They are cracked at the clamps which could also be the issue (see Pic 4), but I think I first want to resolve this priming issue.

Pic 5 is the fuel tank. Can someone confirm the far right is the genny fuel supply?

Pic 6 is a full pic of my generator. Is the top hose on the left a fuel supply return that coincides with the middle inlet and hose in Pic 5?

Re: Generator Issues AGAIN!

Reply #22 – March 19, 2012, 07:27:01 pm

When I primed mine I just took the diesel filter,topped it off with fuel and screwed back on...This was all it needed to pull prime... I took my fuel pump to Napa and they matched me one up. I think it was only like 50 bucks are so
BTW,My old pump worked on and off like it was on its last leg,I took it off, hooked it up to a hose and stuck the hose in a bucket of fuel to see what the flow looked like.
Turned out it was very weak and pumped diesel on and off so I knew it was bad

Re: Generator Issues AGAIN!

Reply #23 – March 19, 2012, 07:54:35 pm

I crack the bleed screw where the fuel line goes into the engine. Run the pump until no more air, then close it off.

Re: Generator Issues AGAIN!

Reply #24 – March 19, 2012, 07:56:59 pm

How do you run the pump?

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