Runs rough and black smoke on initial start

[Strike Fighter]

Hi , I have a trained eye for 802-A and 803-A Gensets , My question would be , I see the fuel saturation on top of the head around injector nut most likely from leaky fuel injection return lines in the past . I see the hard line connected to the injector and the new return lines . What do you see ?

Also remember JP-8 sat in this generator for a extended amount of time most likely unless it was shipped back to the states air bound then it was drained but the remainder of the fuel stayed in the fuel system and JP-8 Can get nasty with time even Gummy . If it were me i would run it for a while with fresh Diesel .....

 

[Light in the Dark]

What you photographed are the metering pumps, not the injectors. If you follow the hard fuel lines up to the top of the engine, the injectors are the items which you plumbed the return line short sections off of (with the barbs).

The barb on the metering pumps (where the soft lines are plumbed to) both need to be set to as close to the push rod tube as they will allow (and be the same between both cylinders. This setting will directly impact available fuel flow to/through the metering pumps.

 

[incorporatedbyinference]

I will check the length I cut the replacement at. I believe I just cut them at what would easily install. I m gonna need to study some more as to how the fuel system works. Thanks for the help.

 

[Light in the Dark]

The length of the soft line is not important... the barb which its installed on, on the metering pumps, rotates. This rotation is what allows fuel to be pumped upwards. If they are not both fueling at the same amount, it can cause running issues. In actuallity its not the barb that rotates, but the lower pin that goes into the fuel rack (you just need to set it properly so the fixed barb appears to be rotated fully open, as close to the pushrod tube as possible)/

Another SS user put this video together about the metering pumps, may shed some light on the assembly: