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The Lister Generator Project Page 5 By now, the genset had about 125 hours on it and had been very reliable. This was about to change... Two days before the hurricane, I was demonstrating the engine to a friend when I noticed a large fuel leak coming from one of the "B" nuts on the fuel injector pump. It was not loose. After a quick examination, I found the line had split open due to crappy quality. No where to be found was an engine shop that could make a new line. I went to NAPA auto parts and bought some 1/4" steel brake line and tried frantically to fabricate a replacement. By using the old "B" nuts, the new Napa brake line and a couple of 1/4" brass ferrules, I was able to make a replacement that actually worked! The question was ....would it hold up?
As the hurricane approached and
the power went off, I gritted my teeth and cranked it up praying the
temporary repair would hold. So two days into the cleanup, the listeroid still chugging away, temporary fixes still holding, I'm beginning to feel a bit better about the whole generator project. Day three, in the morning, I go to the shop to crank up the engine for the days fun. After it's running, I check the oil pressure and notice it's low with the pulses only registering 10 psi instead of the usual 35. As I'm using a $4 Home Depot water pressure gauge for oil pressure, I write it off to cheapo indications and get on with the cleanup. That afternoon, While refueling the engine, I check the oil pressure again.. No oil pressure!!! This thing has been running all day with no oil pressure!! AHHHH! I shut it down and begin to investigate. My first guess which turns to be right, is that the oil pump plunger return spring has broken. Well, broken is an understatement. I see it's been shattered into 7 pieces. A quick search through my junk pile yields a similar looking and feeling spring. I install it, crank it up and it works fine with 35 PSI again. It continues to run with the same spring. Finally, after two hurricanes, and over 250 hours of running, the power comes back on and I relax to ponder the days events. It's also time for an oil change to get it ready for the next hurricane.
I drained the oil through a
fine screen to see what bad things I could find. Amazingly, the screen was
pretty clean. A few more grains of sand, some lint but nothing else, most
importantly, no white bearing material. I pulled the little magnets from the
sump. Here is a summary of the first 250 hours of operation:
oil used :1 quart per 100 hours
Oil leaks:6
I have given up and fixing most
leaks and place cloth diapers under them every morning to catch oil. Just
crappy quality and one must be prepared to have a messy engine. After much searching, I've located some aluminum sealing washers and started placing them under the nuts that have been leaking oil. The results so far are promising as they aren't leaking anymore. Time will tell if this permanently fixes this problem. (didn't work) I still planning on building a concrete generator house this winter and moving the genset out there. This was it can run unattended without worry of a malfunction torching my shop. As this project get underway, I'll start a new page following its' progress. In the new installation, It will have a catch pan under it that will fill a small bottle with a float switch in it. Any significant leaks will fill the bottle and the switch will kill the engine. As expected, building machines like this is akin to tinkering and one must be prepared to experience some difficulty. I am frequently asked if I'd do it again. The answer is yes, only I'd deal directly with the engine factory instead of an exporter. The manufacturers seem quite enthusiastic and will build engines to your specification and adjust quality to meet that requirement as well. Next time, I'll specify an engine that doesn't leak oil, had better injector lines, and is run in at the factory with virgin clean oil so as not to contaminate the case with casting sand and other crud.
The other thing I would do
differently, is to completely tear the engine down and inspect it before
running it the first time. Date: November 2004 The Engine marked "LOVSON" was exported through "LOVSON EXPORTS". The Engine Manufacturer M/s. ANAND ENTERPRISE became aware of my problems. He identified the engine as one of his own and has been following the progress of this project. First of all, he immediately sent me not two but four new injector lines express mail. I installed them and they work fine. He has taken steps to improve his engines in the area's I feel were deficient. It like to give praise to Mr. Patal for his devotion and quick response to my problems. He could have easily ignored me but instead chose to jump in and fix the problem. My hats of to Mr. Patel for his excellent business ethics. He has made other changes to these engines recently including a magnetic oil plug, and breaking using new clean oil to reduce the chance of casting sand contamination.
Mr. Atul
Patel, CEO of Anand Enterprise. His website in
www.poweranand.com . |
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"Sadly,
artificial intelligence will probably never be a match for natural
stupidity." |
