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My new generator (Read 189 times)
Dave
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Re: My new generator
Reply #30 - 10/18/24 at 04:07:26
 
ThumperPaul wrote on 10/17/24 at 16:28:04:
That thing is a TANK!


At 880 pounds with fuel and oil - it does seem to be a bit excessive for just 5,000 watts!  I guess that when you go into battle you want something that is rock solid and going to get the job done.
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Dave
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Re: My new generator
Reply #31 - 10/18/24 at 04:43:56
 
Dave wrote on 10/17/24 at 16:07:32:
 In addition to the fuel level sensor there is a device with an upper and lower float - the upper one is a shut off for the fuel pump that takes fuel from a remote tank and pumps it into the main tank - the lower float senses that the tank is low and shuts off the engine (more on that later).


When everything was back together and I connected the battery and turned things on - the fuel pump would run for 3 seconds and stop....then the low fuel warning light would come on.  The fuel gauge read empty - however there was plenty of fuel in the tank.  I checked the new sender and it was working properly - if I turned on the "Battle Short" switch the fuel pump would run.  A check of the wires at the gauge showed it was properly grounded, was getting a proper signal from the sender in the fuel tank, and the gauge had power - therefore the gauge was bad......however this should not trigger a low fuel warning as the signals to the bad gauge were proper and the gauge does not send a signal to shut the engine down.

I found a thread were a guy had the same problem - when he turned on the "run" switch the pump would run 3 seconds and then stop and the low fuel warning would come on.  The thread stated it was the float switch with 2 senders that causes this.....the lower float tells the system it is out of fuel.  The sender in my tank was in good condition and the floats moved easily - and this problem did not exist prior to me cleaning the tank.

I thought about removing the float sender and looking at it - but first I decided to wiggle the generator around and slosh the fuel a bit to see if the float would move....and it worked!  The bottom float must have been hung up at the bottom and didn't move when I added fuel to the tank.  The fuel pump now runs continuously when the stitch it turned on and the warning light does not come on.  (The fuel gauge is still reading "empty" and a new replacement gauge is in the mail).
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JOG
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Re: My new generator
Reply #32 - 10/18/24 at 05:05:11
 
I'm still confused as to the Why all the complexity of the fuel system. It's got some really trick pump/self bleeding so if it runs outta fuel, ya don't have to crack injector lines and crank it until ya get the diesel to squirt out, but it also has a low fuel sensor to keep it from running out. I'm not against either one, I'm just wondering why they built it that way. I wonder how long it takes for the self purge/prime the pump and injectors if the low fuel sensor fails and ya Do run it out..
I've never heard of a system that would do that.

What is the big solenoid with the bellows and the arm going to the left? Looks a lot like a kill.

If you're running it but the load is insufficient to make it Tach up to avoid the Wet Stack problem, what do you have to do?
Is that problem a big enough deal to make a guy think about changing the exhaust stack design? If it didn't go Up, YaKnow?
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ThumperPaul
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Re: My new generator
Reply #33 - 10/18/24 at 06:15:13
 
Dave, that’s kinda what I was thinking.  It’s definitely battle ready!  It’s cool that it runs on diesel and you have a single common fuel source for all your toys!

I have a little gas powered 3500w (4500w surge rated) generator.  It’s been a true blessing when we’ve had hurricanes and long power outages.  The longest we’ve had to use it continuously was Feb, 2021 when “snowmaggedon” hit Houston and knocked out power for 5 days.  We stayed around 15° for a week - extremely unusual around here.

I am able to run a small 6000btu A/C window unit in the main living area, deep freezer, fridge, TV, LED bulb lamp, and have power leftover to charge phones or use something else small.  I have to turn off the TV or AC to use the coffee maker (gotta have coffee!).  Anything that “makes heat” sucks some power (you know that).  I’ve run the toaster oven and microwave in a pinch and you can hear that engine chugging right up to the 4500 surge rated power.  We don’t use those anymore - I’d rather not blow the generator and lose AC because somebody wanted toast or something.

Cool project!  I like that BEAST!  Hopefully you rarely, if ever, have to use it!
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Re: My new generator
Reply #34 - 10/19/24 at 03:31:48
 
Thumperpaul:

I am not exactly sure how much power I need.  These military generators come in a 3kw single cylinder version with a Yanmar air cooled engine, a 5kw twin with a Lister-Petter designed water cooled engine built by Onan, and a 10kw version with a 4 cylinder version of the Lister-Petter engine.  I believe the 10kw is just too big for our needs and would be wasteful of both storage space and fuel.  I was not sure the 3kw would be large enough to run our furnace if we needed heat.  I will give this 5kw a try and see how it does.  

Most of our power outages are short term and only last a few hours.  We have only experienced one long power outage and it lasted a bit less than a week.  We had a hurricane come through many years ago and it knocked down a large Maple tree in a neighbors yard that took out the power lines, and the power company could not restore the lines until the neighbor got the tree out of the ROW.  During that outage we had a gas 7,500 watt generator and it could easily power everything we needed (we did not run our 3,850 watt electric water heater and would go to my office to take showers).  To run just the fridge and freezers to keep our food fresh only requires the generator to run 30-40% of the day, and we could get by with a much smaller generator for that time as those appliances use 300-600 watts each.  There are small 2kw diesel military generators that look just like the normal contractor style generators that could do the job and only use about 1/3rd gallon per hour.....I may watch and see if I can find one of those at a good price.




JOG:

The solution for the wet stacking problem - is to make the generator work a bit.  When folks start the generator to keep it in operating condition and ready for an "emergency" - some of them don't hook up any load and then engine just doesn't work hard enough to get up to operating temperature.  The condition not only affects the exhaust - the piston and cylinder are also affected.  The solution is to hook up a load and make the engine work a bit - they recommend a 50% load or more and let it run for an hour minimum.  For this generator that would be 2,500 watts or more.....just a couple of small space heaters.  I don't know how often it needs to be run - once every couple of months might be fine as long as the batteries are put on a tender regularly.

The original generator has large terminals for hooking up the electric to provide power to something - the only outlet built into the machine is a double 110V outlet with a 10 amp limit.  The previous owner installed a 50 amp outlet on the side of the machine - it is gray and doesn't really match the military theme.
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Re: My new generator
Reply #35 - 10/19/24 at 03:50:06
 
I bought some paint to cover the gray on the outlet and make it look more appropriate.  The original paint has bleached out a bit from sitting outside for 20 years - however the new paint matches better than the gray did.

The little cover gets bolted onto the top of the cabinet with a rubber gasket in between.  I will wait a few days for the paint to cure before I install it.
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ThumperPaul
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Re: My new generator
Reply #36 - 10/19/24 at 05:26:19
 
Your attention to detail amazes me, Dave!

The 5kw seems like a good size.  Good balance between ample supply and fuel consumption.

I need to go look at your other post and see how you’re doing with the pesky oil leak.
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Re: My new generator
Reply #37 - 10/19/24 at 05:34:59
 
ThumperPaul wrote on 10/19/24 at 05:26:19:
I need to go look at your other post and see how you’re doing with the pesky oil leak.


That has been on hold for a while........I need a good clutch cover to polish up and install.
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Re: My new generator
Reply #38 - 10/19/24 at 06:02:52
 
Dave wrote on 10/19/24 at 05:34:59:
ThumperPaul wrote on 10/19/24 at 05:26:19:
I need to go look at your other post and see how you’re doing with the pesky oil leak.


That has been on hold for a while........I need a good clutch cover to polish up and install.


That’s what I wondering…if you got a new cover installed.  Winter project.
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Re: My new generator
Reply #39 - 10/20/24 at 11:02:54
 
JOG wrote on 10/18/24 at 05:05:11:
What is the big solenoid with the bellows and the arm going to the left? Looks a lot like a kill.

If you're running it but the load is insufficient to make it Tach up to avoid the Wet Stack problem, what do you have to do?


The solenoid with the bellows is the fuel shut off.  When the power is on it pulls open - shut off the power and it closes and shuts off the fuel flow.

The engine always runs at 1,800 rpm to provide 60hz of power.  The throttle opens up when a load is applied to maintain the 1,800 rpm.  You need to have the throttle opened up enough that the engine makes some heat in the cylinders and exhaust.....running the engine without any load just doesn't get things adequately hot to burn the fuel properly.  Never had this problem with any diesel tractor, car or truck - but it seems to be an issue in generators that run at constant speed (if they are not properly exercised with a 50% or higher load).
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Re: My new generator
Reply #40 - 10/20/24 at 17:47:45
 
Awwrite,, got it.
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