Fun stuff: cleaning fuel pumps in our 003A the easy way

[peapvp]

So, today we cleaned up the first fuel pump which had gummed up sitting behind our shop.

Remove first fuel pump, open pump button






push ball down and spray out with carburetor cleaner. Connect pump to 24 VDC source. Pump should draw between 1A to 1.5A
Spray cleaner into outlet holding pump upright.

When the gunk dissolves, the tic tic sound increase in volume.

Reassemble and install back in Generator. Remove feed line from tank and place in container with paint thinner. Do not connect the hose to the secondary pump yet.

Set start stop run switch to run prime and let run until paint thinner comes out of pump outlet.

Put feed hose now in container with industrial isopropyl alcohol 99.9%

Set to run prime

if no isopropyl alcohol comes out, spray some carburetor cleaner into outlet while pump is running.

The tic tic sound should significantly increase.

When alcohol comes out of outlet with a full stream, stop pump.

connect hose to secondary pump and open drain on first fuel filter.

Set to run prime until alcohol comes out of drain on first fuel filter

stop pump

connect feed line back to tank

check tank first for rust inside from filler



Clean tank first and fill with fresh diesel with or without seafoam

Set to run prime until a good quart of fresh diesel has drained out of first fuel filter

close drain on first fuel filter

let pumps run for several minutes for IP to prime

then pre glow for 30 seconds and start generator

expect plenty of white smoke and engine stutter

once fuel system is fully free of possible air, Genset will run as normal



Autostart board Serial #000 installed on October 8th, 2013

Genset has been outdoors in Kansas since this day and in any weather.

Lowest temperature -10F
Highest temperature 109F

 

[peapvp]

Thought I add a few more pictures for your enjoyment

we are using the Genset for 3 Phase 208/230 in our shop with a remote switch inside the building so we don’t have to go outside to start the genset











And off course the professionals among you probably noticed that I had the wrong wrench in front of the fuel pump to remove the bottom cover

this would be correct

 

[Guyfang]

That's something I will have in my head until I kick the bucket. 7/8th wrench. And I used a half moon wrench. Better grip and range of motion.

 

[peapvp]

That's something I will have in my head until I kick the bucket. 7/8th wrench. And I used a half moon wrench. Better grip and range of motion.

@Guyfang interestingly, on this particular pump the 7/8 worked like a charm and was a 100% fit......

 

[Guyfang]

There were, some pumps, that needed a 3/4 and some that had a 7/8. In the 70's, we had a hard time getting parts. One of the guys in the motor pool was a Track mechanic. He told us about pumps that fit on the M48 and M60 tank, that should fit. So we tried them. Different NSN and part number, but dropped right in the hole and fit. They were 3/4 wrench. So at 03:00 and you were dragging butt, if you had to clean the fuel pump strainers, you had to try and remember to take both wrenches. For us, it was at least once a week thing to drop the strainer/filter. Sometimes more often. PITA