Diesel generator that won't start.

Hi,
My neighbor gave me a 5000 watt diesel generator before he moved. It has no name brand, just c500d revolution. I think it's a chinese made knockoff of a Yanmar generator. Anyway, it's never been started, and he didn't give me a manual, and he's gone. I tried to get it running today, but it wouldn't start. Fuel is getting from the tank to the engine. I have it jumpered to my truck, so the starter has full power. I'm wondering if most diesels need to be primed, and if so, how should I go about priming it. I tried removing the injector line, and pouring diesel in there, but that didn't work. Any ideas? Thanks,

-Tim

Loosen the fuel lines at the injectors and keep cranking in 5 second intervals until diesel flows out from the lines.

Correct loosen all injector lines while cranking see if fuel coming from injectors. If it has a fuel filter or bowel check it for dirt, check lines if rubber for cracks or suction loss. make sure fuel is getting to injectors confirm once you have fuel check electric wires etc. how old is unit? could have a compression problem. good luck wish i was there to help you let me know if u get it running. Bob Raynor

Hi most diesels require the fuel to be heated first so look for a glow plug and if you cannot find the glow plug switch squirt just a small amount of starting fluid into the carb.

Hey Dave Smith, diesel engines don't have carbs...

I think you meant to say "...squirt a small amount of starting fluid into the air inlet (take the air filter off first)."

I have a Izumi diesel generator that I can not get started. I have tried pretty much everything you guys have suggested. The only way I can get it to crank is with starting fluid but it wont stay running.

Tim in Elk, California said: Hi,
My neighbor gave me a 5000 watt diesel generator before he moved. It has no name brand, just c500d revolution. I think it's a chinese made knockoff of a Yanmar generator. Anyway, it's never been started, and he didn't give me a manual, and he's gone. I tried to get it running today, but it wouldn't start. Fuel is getting from the tank to the engine. I have it jumpered to my truck, so the starter has full power. I'm wondering if most diesels need to be primed, and if so, how should I go about priming it. I tried removing the injector line, and pouring diesel in there, but that didn't work. Any ideas? Thanks,

-Tim

check to injection pump solenoide make sure dc volts over there how much needed in there, if its ok removed and test injector they are fire..?make sure engine getting air or not??

i have a genset MG 6000 SY, i just got it to run our catering trailer was working when i collected it but had a fuel leak replaced all the fuel hoses and copper washers for the injector hose cleaned it but now will not start i have bled it and seams to be getting fuel to the injector but will not fire at all,any ideas

if generator runs with easy start then the cam for fuel pump is not in correct place and or has sheared ,sorry but only to find out for sure is take fuel pump off again ,
you done it once

david smith in Olney, Illinois said: Hi most diesels require the fuel to be heated first so look for a glow plug and if you cannot find the glow plug switch squirt just a small amount of starting fluid into the carb.

don't answer a question you know nothing about. Diesels don't have carbs, never put starting fluid in a diesel engine, and diesel fuel doesn't require heating before use unless it severely cold out and the fuel has solidified (and that doesn't happen much especially with the additives they put in it now), the glow plugs are there to heat the air or the block in some cases before compression of said air to raise the temp. before the diesel is injected.
-Diesel Generator Mechanic for Lockheed Martin

I am looking for generator mechanics in the Atlanta metro area who would like to work for themselves as Independent Contractors, also have slots for employees. The pay is good (depending on expierience) and you can be your own boss. I am starting a generator maintenance firm and looking for techs to work the Atlanta area and surrounding states to AL, FL, SC and TN mileage pay is very good, almost double or triple what CDL drivers make in addition to windshield pay.

You will need..

Your own tools. Your own truck and atleast 3 years of expierience as a Generator Mechanic.

if you are interested then e-mail me at adam_ant72@yahoo.com and I will keep you in mind for jobs that come up.

PLEASE HELP> We have a Lister (HawkPower) that one day quit under load, we found that when the 2 AC units are on at the same time is when it quits. the genset is 18KW and more than enough for the load. so we had to keep the engine revved to keep it runing. we know that it is not a fuel or battery issue, any ideas?

H.Dermish in North Zulch, Texas said: PLEASE HELP> We have a Lister (HawkPower) that one day quit under load, we found that when the 2 AC units are on at the same time is when it quits. the genset is 18KW and more than enough for the load. so we had to keep the engine revved to keep it runing. we know that it is not a fuel or battery issue, any ideas?

My first thought is that you may not have enough fuel flow but that cause it to die after a few seconds there would be a delay. If the genset dies immediately after applying load, then your problem is much worse. Either your main windings or your exciter windings or even your voltage regulator. Remove each main gen wire one at a time and check for continuity to ground (while it's shutdown) If you have continuity it's f*&#@d. The same with the two exciter wires. If the volatge reg is bad there are usually no tell tale signs, but the proper manual will have the tests and values of resistance necessary. The power transformer could also be the problem, as power passes through the windings it gets hot and in some cases can melt the insulation between the loops of windings. Also when electricity passes through electricity passes through metal the metal contracts so it could have a snake affect and only short out when you put a load to it. If that's not the case check your connections maybe you have a leak to ground somewhere (the AC units could have a short too) This would usually blow a fuse unless some bypassed it. There is a lot of other diagnostic steps to do too. If you feel unable to attempt these, hire a GenMech that's what we are here for.

Henry'
Thanks for the reply, i wish there was a GenMech around here! anyway the genset runs, we just have to revved it up to stay running when it reaches a certain load.

I need a parts list for an Izumi 4000T Diesel generator C-E. Rated Voltage 120/240
Rated power 3000W

using DP6500ATS of Everlast Generators? I need references

thanks

your website is www.everlastgenerators.com/products-details-47.html, but i dont know.

Was using a borrowed Izumi 6700T diesel generator when it stopped running while under medium load. Had been running it for several days without any problems. Fuel filter is not stopped up - tested it. My associates and I are novices with diesel engines. What elements would be the most likely problems areas to check?

Any recommendations for good small diesel engine mechanics in the Houston area?

The fuel filter has no markings. It is a pleated cartridge about 3.25 inches long and 1.125 inches diameter. What brand and item number should I be looking for and where can I get one?

Still without electric power in hot Houston thanks to Ike and sluggish CenterPoint Electric Power!!

Floyd in Fort Worth, Texas said: I need a parts list for an Izumi 4000T Diesel generator C-E. Rated Voltage 120/240
Rated power 3000W

Floyd,

I have a generator Operation Instruction small manual and a Owner's Manual for the Air Cooled Diesel Engine and they include the Izumi 4000 series. The Owner's Manual which includes parts lists is exactly like the one I downloaded from the EmergencyPower.com site at link: www.emergencypower.com/photos/dieselenginemanual.pdf

The pdf file link on their site is listed as: LA186 Diesel Engine Owners Manual. The manual covers three engine series: 170F, 178F, and 186F. Take a look at the pdf file.

Hey Gentlemen,

Atlanta area generator mechanic here.

What type of load did you have connected and are you sure that the amps didn't knock it off-line?

Are you sure it was only a medium load?

Could it have overheated?

Is the fuel pump OK?

Air filter clogged?

Schmutz (water, dirt, crap) in the fuel tank? Or bad fuel?

Voltage regulator not regulating the voltage and the unit is sensing the wayward readings and shutting the unit down for over/under voltage?

@Generator Maintenance Specialists in Atlanta,
I don't know about 'George5', but in my case "PLEASE HELP> We have a Lister (HawkPower) that one day quit under load, we found that when the 2 AC units are on at the same time is when it quits. the genset is 18KW and more than enough for the load. so we had to keep the engine revved to keep it running. we know that it is not a fuel or battery issue, any ideas?"
All is checked but the voltage regulator, how do i know if it is the cause?

George....thanks for the parts list that I requested, that is what I needed....Floyd

To: Hader in Corpus Christy

The voltage regulators often are not able to be tested but check your amp rating on your AC units and on the generator. It may say "X" amount of amps on the AC unit but that is continous rated and does not account for spikes when the compressors kick on. The compressor draws a large amount of current from the generator often in spikes, way much more than say a TV or a computer. It's basically like a pressusre washer sucking the water through the hose faster than the spigot can provide it and knocking the generator offline.

@Generator Maintenance Specialists,

Thanks for the reply, the genset never had a problem with the same load before and now that is revved up manually runs great, i just rather it did it on it's own.

Ran out of character space in my previous reply.

Generator Maintenance Specialists in Atlanta, Georgia said: Hey Gentlemen,

Atlanta area generator mechanic here.

(Deleted questions that have been answered.)

Q: Schmutz (water, dirt, crap) in the fuel tank? Or bad fuel?

Q: Voltage regulator not regulating the voltage and the unit is sensing the wayward readings and shutting the unit down for over/under voltage?

A: Bad fuel might be involved in this problem. The freshly purchased Valero Service Station diesel fuel looked more like yellow-green antifreeze when I poured it into the tank than the brownish color I had expected. It was oily like diesel fuel should be and had the odor of diesel. It came out of pumps set up for trucks. How do we make a determination about this fuel? If this was ag diesel, should it have run OK?

A: If the voltage regulator is the problem, would it keep the diesel engine from starting? The medium load output voltage was usually 119-120 volts, but the heavy load surge output would drop down to around 104 volts and the engine speed would drop some.

Centerpoint Energy restored electric power 2 days ago (16 day outage) so hopefully we won't need generators again soon. Also have a Honda and an Onan (with B&S engine) that need gasoline engine repairs. Repair shops backlogs are 2-3 months.

Thanks for the insight and pointers!!

Tim in Elk, California said: Hi,
My neighbor gave me a 5000 watt diesel generator before he moved. It has no name brand, just c500d revolution. I think it's a chinese made knockoff of a Yanmar generator. Anyway, it's never been started, and he didn't give me a manual, and he's gone. I tried to get it running today, but it wouldn't start. Fuel is getting from the tank to the engine. I have it jumpered to my truck, so the starter has full power. I'm wondering if most diesels need to be primed, and if so, how should I go about priming it. I tried removing the injector line, and pouring diesel in there, but that didn't work. Any ideas? Thanks,

-Tim

one of the ways of primiing is by loosing the fuel line on number 6 depending on how many injectors it may have. but looseing to the last injector fuel line then cranking until fuel pours out and then tighten while the fuel is comming but you can see when the air is comming out also.

H.Dermish in North Zulch, Texas said: PLEASE HELP> We have a Lister (HawkPower) that one day quit under load, we found that when the 2 AC units are on at the same time is when it quits. the genset is 18KW and more than enough for the load. so we had to keep the engine revved to keep it runing. we know that it is not a fuel or battery issue, any ideas?

Start one ac at a time you are over loading the gen on start or in rush of the ac's

George5 in Houston, Texas said: Was using a borrowed Izumi 6700T diesel generator when it stopped running while under medium load. Had been running it for several days without any problems. Fuel filter is not stopped up - tested it. My associates and I are novices with diesel engines. What elements would be the most likely problems areas to check?

Any recommendations for good small diesel engine mechanics in the Houston area?

The fuel filter has no markings. It is a pleated cartridge about 3.25 inches long and 1.125 inches diameter. What brand and item number should I be looking for and where can I get one?

Still without electric power in hot Houston thanks to Ike and sluggish CenterPoint Electric Power!!

check oil level and pressure and coolant level if it is liquid cooled, bring the filter to napa and they can match it

todd in Anchorage, Alaska said: Start one ac at a time you are over loading the gen on start or in rush of the ac's

they are not started at the same time, but when running at the same time is when we have the problem. and once again , the genset is bigger than the load. it ran the same load for months.

YOU CAN POSSIBLY HAVE A CLOGGED FUEL FILTER. IF YOU NEVER HAD THAT PROBLEM BEFORE, I WOULD CHECK THE FILTER. WHEN YOUR UNIT CALLS FOR MORE FUEL, AS THE LOAD RISES.. IT IS VERY POSSIBLE THAT YOU ARE NOT RECIEVING THE PROPER AMOUNT OF FUEL TO KEEP THE ENGINE RUNNING AT RATED SPEED FOR THAT PARTICULAR LOAD. THAT USALLY IS THE FIRST CHECK I WOULD MAKE.. AND POSSIBLY THE CHEAPEST..

Thanks for the reply, we know so far it has nothing to do with any fuel issues or the solenoid. it has to be the voltage regulator.
I'll update when we find out.

I am trying to get my 12 month old Yanmar copy (ie Chinese made) 170F air cooled diesel water pump running again. I suspect a fuel blockage. Just wondering if there are any "tricks" to removing, cleaning and replacing the fuel pump and injectors. I want to inspect and clean them. (The problem was/is: Pump was running well until the last attempt to use it when, soon after starting easily, it began to blow out black sooty exhaust, slowed down and then stopped. After that it would at first fire for a few revolutions and then die. Then would not fire without the starter motor cranking it over.)

Suggestions gratefully received. Cheers.

Hader in Corpus Christi, Texas said: @Generator Maintenance Specialists,

Thanks for the reply, the genset never had a problem with the same load before and now that is revved up manually runs great, i just rather it did it on it's own.

Well, your still having this problem. You have electricity, but it won't govern itself. Often a generator has a governor control unit. This may be electrical or mechanical. If electrical there is no sure fix, just save time and replace that component, (check your wiring diagram first to ensure it's connected properly and your connections are good you know corrosion or looseness) If Mechanical, they usually run on oil pressure. If the oil is contaminated it may have clogged up the journals on this component. Removal is easy and an overnight stay in parts washing fluid should be enough. Installation is also easy don't worry it doesn't have to be timed. I know you say fuel isn't a problem but that is where I would begin, yes you have flow but do you have pressure, is your fuel pump blocked slightly (this may have to be timed if you have more than one cylinder) At the injector pipe where it connects to the injector the fuel should shoot out with force, don't worry it doesn't hurt there. If there is just a trickle check your filter first, by checking flow before and after the filter unless the only thing before the filter is the fuel tank LOL. If you have good flow all the way to the injector, good. Maybe you have a clogged injector, this would cause a sputtering or spitting sound as it misfires accompanied with black smoke (unburned diesel). It's not really good for it to be reved up without load, it's like reveing your car in nuetral, you could cause some major damage and then repair may not be an option. I hope part of this helped. That'll be $450 LOL!

Henry in Hinesville, Georgia said: Well, your still having this problem. You have electricity, but it won't govern itself. Often a generator has a governor control unit. This may be electrical or mechanical. If electrical there is no sure fix, just save time and replace that component, (check your wiring diagram first to ensure it's connected properly and your connections are good you know corrosion or looseness) If Mechanical, they usually run on oil pressure. If the oil is contaminated it may have clogged up the journals on this component. Removal is easy and an overnight stay in parts washing fluid should be enough. Installation is also easy don't worry it doesn't have to be timed. I know you say fuel isn't a problem but that is where I would begin, yes you have flow but do you have pressure, is your fuel pump blocked slightly (this may have to be timed if you have more than one cylinder) At the injector pipe where it connects to the injector the fuel should shoot out with force, don't worry it doesn't hurt there. If there is just a trickle check your filter first, by checking flow before and after the filter unless the only thing before the filter is the fuel tank LOL. If you have good flow all the way to the injector, good. Maybe you have a clogged injector, this would cause a sputtering or spitting sound as it misfires accompanied with black smoke (unburned diesel). It's not really good for it to be reved up without load, it's like reveing your car in nuetral, you could cause some major damage and then repair may not be an option. I hope part of this helped. That'll be $450 LOL!

Oh, hey if you are checking your injectors be very careful the fuel comes out of here with such force that it will blow a hole through your hand! Have these checked by a professional, any diesel shop should have a bench tester for injectors and they have the knowledge to use it.

Gary Benson in Dallas, Texas said: I have a Izumi diesel generator that I can not get started. I have tried pretty much everything you guys have suggested. The only way I can get it to crank is with starting fluid but it wont stay running.

that is because it now feeds off of that stuff the "starter fluid" like a drug....anyways the first steps are.....to make sure that your fuel tank is not dirty with trash and if not....second go to the feul pump sometimes those things do go out and the only way to know is that it clicks when you turn it to run not start.....if it does click "it is a repeated clicking noise" if it does click then loosen the line that is on the side of the fuel pump that goes to your fuel filter. if fuel comes out of that with out starting the engine the fuel pump is good.....next you go the the filters both filter must be in good shape if those look dirty but before you take those off make sure that the engine switch is turn off take those off look at them if they look dirty then replace them if not make sure that fuel is getting to the filter....now remember that there are two filters one is the water seperator and the other looks like a lawn mower filter.

Just as the gentleman said earlier you either have a fuel flow issue or an air flow issue. The best course of action would be to check both and see of you have an obstruction in either place. Blocked fuel filter, inoperable fuel pump, water in the fuel, blocked air filter, critters in the air intake, a sucked up plastic bag or anything like that could cause it not to fire up like it should. I am assuming that noting bad happened like it was run over by a car or no one poured cherry syrup in a cylinder. Check us out..

-John
Generator Maintenance Specialists (Atlanta)

www.realpages.com/sites/genmaintspc

Yes very good John, I think the man better take your advise. Hope your diesel is dazzeling. Best.

wardawg in San Antonio, Texas said: YOU CAN POSSIBLY HAVE A CLOGGED FUEL FILTER. IF YOU NEVER HAD THAT PROBLEM BEFORE, I WOULD CHECK THE FILTER. WHEN YOUR UNIT CALLS FOR MORE FUEL, AS THE LOAD RISES.. IT IS VERY POSSIBLE THAT YOU ARE NOT RECIEVING THE PROPER AMOUNT OF FUEL TO KEEP THE ENGINE RUNNING AT RATED SPEED FOR THAT PARTICULAR LOAD. THAT USALLY IS THE FIRST CHECK I WOULD MAKE.. AND POSSIBLY THE CHEAPEST..

Sounds logical to me!How do I change the Fuel filter with out changing theFuel Pump(Honda Civic 2001).

Thabks again wardawg.Cathy

Peter F. in Melbourne, Australia said: I am trying to get my 12 month old Yanmar copy (ie Chinese made) 170F air cooled diesel water pump running again. I suspect a fuel blockage. Just wondering if there are any "tricks" to removing, cleaning and replacing the fuel pump and injectors. I want to inspect and clean them. (The problem was/is: Pump was running well until the last attempt to use it when, soon after starting easily, it began to blow out black sooty exhaust, slowed down and then stopped. After that it would at first fire for a few revolutions and then die. Then would not fire without the starter motor cranking it over.)

Suggestions gratefully received. Cheers.

I have the exact same condition with the same Chinese made generator, but I have three of them, one runs good and the two others blow out black sooty exhaust and than slows down and stopped, I have swapped the fuel injector pump and the fuel injector with the one that runs to one of the engines that doesn't and still won't start, it will try and will fire with the starter helping it but not on it's own. I put injector pump and the injector taken out of the bad motor and put them in the good running motor and it still runs good, so I know the injector and pump are good, swapped fuel tanks(filter in tank) to no avail, These engines have very low hours on them so I don't think the compression is the issue, in fact, with the two that I can't get going, they will come up on the compression stroke and the starter won't have enough power to take it through the cycle, it will when first cranking it but once it fires and dies any restarts results in stopping on the compression stroke. I don't know it I'm not getting enough fuel or too much, they do smoke quite a bit when first started, any comments appreciated, Yooper

Yooper,
Try taking out the fuel cut-off solenoid and remove the plunger and spring and then re-install the solenoid. Then bleed all the air out and start the engine. You will have to shut the engine off with the throttle lever. If that works check for loose connections and low voltage to the fuel cut-off solenoid. I will assume it is not the solenoid since you said you changed the injector pump. Good luck.

I have a 655 jd compact tractorhitting on 2 cyl's when bleeding injectors the one clostest to the fan just keeps blowing air even running the motor for several minutes any ideas thanks Jammer

The most likely cause is a fuel line or bad gasket at the fuel filter. It could also be a bad injector pump. Look very closely for cracks or pinholes that will allow air into the injector pump. Good Luck

I have a military 10KW diesel generator. It has a mechanical governor. When put under a load of any kind (75% or 10% doesn't make a difference) it runs ok for about 5 to ten minutes then wants to die. I am pretty sure it is getting fuel and the governor is working B/C when it dies there is black smoke from the exhaust and sut like the diesel isn't being burned completely. I am lost please help.

matt in Warren, Ohio said: I have a military 10KW diesel generator. It has a mechanical governor. When put under a load of any kind (75% or 10% doesn't make a difference) it runs ok for about 5 to ten minutes then wants to die. I am pretty sure it is getting fuel and the governor is working B/C when it dies there is black smoke from the exhaust and sut like the diesel isn't being burned completely. I am lost please help.

Air or liquid cooled?

Air cooled: Those particular gensets are problematic with the battery charging system. Disconnect the main negative. Remove the blower housing these are 1/2 and 3/8. remove the 3/8 bolts to the top air shroud as well. A stator is behind the blower wheel and these two wires coming out near the fuel injection pump should be checked for a short. Isolate (disconnect) these wires at the terminal board below the aluminum component (regulator/rectifier). Set your multimeter for audible countinuity, attach one lead to the wire and the other to ground (anywhere on the gen) make sure you get bare metal. If you hear a tone this component is defective. Repeat for the other wire. If this checks out good, move on the the regulator rectifier. This check is easier. Replace the blower housing correctly (do not damage the oil cooler). WARNING! Rotating blades! Re-attach the main neg. Start the gen, remove the main neg battery cable at the battery terminal for a count of three and reattach the cable to the battery. If the set dies within these three seconds the regulator/rectifier is blown and has to be replaced. Do not run the gen for prolonged periods without the batteries hooked up because unresticted pulsating DC power will blow the regulator/rectifier.

Liquid cooled: same type of check only disconnect the main negative at the battery. This gen isn't as sensitive but still prolonged use with unattached batteries can damge th alternator.

Let me know what you find.

-Henry (Generator Mechanic for Lockheed Martin)

while cranking these diesels for extended periods, trying to start them, don't use starting fluid, usesilicone spray lube, or wd 40 to give the upper end some lubrication, it also helps spin faster. i had a olds 5.7 diesel once and it must crank a MINIMUM of 500 rpm to start. just a note to you guys

I am a generator field technician with 18 yrs plus experience. i am Kohler certified generator,ATS,and Marine generator.. i have experience with other models cat. honda,generac,winco,onan etc i am also detroit diesel certified 60 series&EGR. two stroke MTU have all tools needed just need job. looking for work in the state of illinois. i am willing to travel..please reply to AL. e-mail alicat920@att.net thank you

alicat in Belleville,
I am having a problem seperating a kohler 10kw electric plant (104cop63 96344a) from the Perkins 4-107. removed bolts from bellhousing but they will not seperate. Any help, please.

It's probably hung up on the gen bearing which is attached to the main rotor. Using a rubber mallet strike the stator near the mounting point of the engine. Using a brass drift strike with regular hammer at the end where the gen bearing is visible. If it still won't come free a puller is required. Be careful not to damage the stator or bearing if you are planning on re using it.

Is there anyplace a set screw could be hidden and holding it up also?

Well I would definitely rule out a set screw but it is highly unlikely. I have never encountered one. Like I said a puller might be your best shot.