MEP-003A

[Johncar48]

Yes Sir, 19v

 

[Guyfang]

And the batterys are 24VDC?

 

[Johncar48]

yes Sir and they are new and freshly charged.

 

[Guyfang]

If you take the P66 wire off the K5, and touch a hot wire, say from the positive pole on the gen set and touch K5-1 the Solenoid moves?

 

[Johncar48]

solenoid moves up and started motor kicks in

 

[Guyfang]

I may have asked before. Its late here, and I am slowing down. But with CB2 pushed in, how many volts do you have at S1-11 & 25

 

[Johncar48]

Go relax and I’ll get back to you tomorrow. Forgot you’re in Germany.

 

[Guyfang]

Will be here till 24:00

 

[Johncar48]

25.3V at both S1-11&15

 

[Johncar48]

Voltage at batteries also reads 25.3V

 

[Johncar48]

I just tested K2 relay and with CB2 pushed in, I get 25.3V incoming and 18.2V outgoing. Haven't looked at wire numbers yet. could this be an issue?

 

[Johncar48]

My bad, that should have read K3 relay

 

[Guyfang]

No. the relay is not the problem. Your set turns over, but will not engage the K5.

If you have 25.3 VDC input to the S1, and 18-19 volts output from the S1, then you could have a bad or dirty S1. Or loose connectors/screws. Or wires that have broken a few strands of wire inside the ring connectors. I would suspect dirty first. There are contact sprays that can be used to clean contacts. @Ray70 can you give some insight as to what might be a good contact spray. All the ones I know are German.

 

[Ray70]

Lots of guys here use Deoxit contact cleaner, available at Amazon.
Your local parts stores will probably have CRC contact cleaner in stock, which is also a good choice.
S1 has a bunch of holes around the back side. Spray the cleaner inside, let sit, spray more and exercise the heck out of the switch, then spray again!

 

[Johncar48]

Well the gov. Solenoid is finally picking up but not getting fuel to engine. Fuel is coming out of fuel tank return line so going to have to pull injector lines I guess.

 

[Guyfang]

Rather then me read for ever in the thread, did this gen set ever work right? Or better asked, when did you see it work last?

 

[Ray70]

If I recall correctly John, you had the machine running good about 6+ months ago, but then let it sit, which is when the problems began?
I am curious if the plunger in the injection pump has gotten stuck in the outward position ( a common problem when these machines sit for extended periods ) 6 months is not a real long time, but lately with the poor quality of this low sulfur diesel we have been seeing issues sooner and sooner when machines sit with untreated fuel in them.
If you confirm fuel is reaching the IP ( and trickling back to the tank ) the solenoid is retracting, the linkage and lever on the IP is lifting fully upward and there is no fuel coming from the injector lines when cranking, the next step would be to inspect the plunger for proper movement, incase it has stuck in the outward position.

 

[Guyfang]

Agree 100%. Those were my thoughts.

I assume, always a bad thing to do, but assume that you have not fooled with the K5 linkage. Because if the linkage is not adjusted right, the K5 may not be opening up the IP far enough.

So, the DETOX worked? Or did you find something else?

 

[Johncar48]

When I first got it, it was in pretty bad shape. 1977 model with 1527 hrs on it. Got it running and itran pretty good and then started going down hill. All seemed to trace back to IP& injectors so sent them off to Ray for rebuild. After they the unit ran great with no issues. Last ran about 6 or 7 months ago then sat and that’s when all these issues started. Uses no oil, doesn’t smoke at all.

 

[Johncar48]

So we have fuel (1 oz ATF per gal diesel) going to IP but no fuel to injectors.