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Onan DJE Running Away


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  #1  
Old 11-01-2017, 11:13:29 PM
John Deere 123 John Deere 123 is offline
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Default Onan DJE Running Away

Hi everyone, I'm having trouble with my onan dje gen set. It ran fine for 3 hours then suddenly started running away and blowing lots of smoke, I had to block the intake in order to shut it down. I took the injection lines off and moved the linkage to the off position and fuel still came from one injection pump port so I'm guessing my pump stuck. Every thing seems to move freely on the pump. It sat for 7 years with out running. Injection pump is zexer made under Bosch. What is wrong? Any help Would be greatly appreciated.
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Old 11-01-2017, 11:16:08 PM
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Billy J Shafer Billy J Shafer is offline
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Default Re: Onan dje running away

Most likely pump needs an rebuild.
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Old 11-01-2017, 11:26:11 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan dje running away

I'm confident I can take it apart but just trying to figure what could be the problem in the pump. Its only the one side I believe
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Old 11-02-2017, 08:02:15 AM
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Default Re: Onan dje running away

The only other thing is a gov problem.
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Old 11-02-2017, 09:29:38 AM
John Deere 123 John Deere 123 is offline
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Default Re: Onan dje running away

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Originally Posted by Billy J Shafer View Post
The only other thing is a gov problem.
I held throttle linkage in the off position and it still was running on one cylinder I believe. But I'll check the gov
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Old 11-02-2017, 11:37:12 AM
AngrySailor AngrySailor is offline
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Default Re: Onan DJE Running Away

How much head pressure is the fuel at the pump inlet or how much pressure is your lift pump? "Fuel still flowing from one injector line" that could be normal if the pump is in bypass, it would have to overcome the spring in the delivery valve though and your injector would have to be stuck open or spring broken to flow fuel, also combustion pressure would be coming out the injector inlet if that was the case. Turn the engine with the injector lines off and see if fuel stops and flows from another pump. Also check it's not getting crankcase oil from anywhere or even an oil bath air cleaner can cause a runaway.
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Old 11-02-2017, 12:41:12 PM
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Default Re: Onan dje running away

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Originally Posted by John Deere 123 View Post
I held throttle linkage in the off position and it still was running on one cylinder I believe. But I'll check the gov
I forgot you said that. Yes i would check the fuel system or for running on oil.
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Old 11-02-2017, 01:08:57 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

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Originally Posted by AngrySailor View Post
How much head pressure is the fuel at the pump inlet or how much pressure is your lift pump? "Fuel still flowing from one injector line" that could be normal if the pump is in bypass, it would have to overcome the spring in the delivery valve though and your injector would have to be stuck open or spring broken to flow fuel, also combustion pressure would be coming out the injector inlet if that was the case. Turn the engine with the injector lines off and see if fuel stops and flows from another pump. Also check it's not getting crankcase oil from anywhere or even an oil bath air cleaner can cause a runaway.
I started it again today and it ran away again but this time I shut it down by loosening the injector lines. One injection line had no affect (no fuel came out) the other injection line shut it down. Not sure on fuel psi but it is pumping fuel.

---------- Post added at 01:08:57 PM ---------- Previous post was at 01:02:41 PM ----------

Oil level is right, has a paper air filter and I un hooked the crankcase breather from the intake manifold and still ran away again so I'm guessing something is in the injection pump. Maybe varnish could be the culprit?
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Old 11-02-2017, 01:13:37 PM
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Default Re: Onan DJE Running Away

It sounds like it has a break away rack inside the pump and one barrel is stuck full delivery
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Old 11-02-2017, 01:19:13 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

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It sounds like it has a break away rack inside the pump and one barrel is stuck full delivery
That is what it acts like. I'm hoping nothing broke. It was under no load when it happened.
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Old 11-02-2017, 01:27:10 PM
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Default Re: Onan DJE Running Away

It's been a while since I worked on a small pump, see if you can get access to the rack and gently work it back and forth check for drag, varnish or any binding.

---------- Post added at 01:27:10 PM ---------- Previous post was at 01:25:27 PM ----------

Oh, I'm sure you know but be very careful cracking injector lines loose, the fuel will penetrate your skin no problem.
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Old 11-02-2017, 01:27:10 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

Had it running for probably 10 minutes before it happened. Was running smoothly as well, if it was under a load or was hunting it would be one thing but it just happened instantly
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Old 11-02-2017, 01:29:58 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

Had the pump off and seems to work freely but sometimes I could feel a bind in the rack.
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Old 11-02-2017, 01:31:35 PM
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Default Re: Onan DJE Running Away

Are you just moving the rack or can you actually see the individual barrels rotating?
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Old 11-02-2017, 01:36:58 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

I'm just moving the rack which is moving the small gear as it should. Ill take the pump off and take it apart. Cant see the barrels
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Old 11-02-2017, 01:42:09 PM
len k len k is offline
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Default Re: Onan DJE Running Away

Quote:
Originally Posted by AngrySailor View Post
Oh, I'm sure you know but be very careful cracking injector lines loose, the fuel will penetrate your skin no problem.
VERY HIGH pressure, I read the medical solution is amputation!!!! SERIOUSLY, NOT KIDDING !!
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Old 11-02-2017, 01:45:36 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

Yeah can be lethal in some case
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Old 11-02-2017, 01:48:04 PM
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Default Re: Onan DJE Running Away

I'm. It familiar with this specific pump but... can you remove the delivery valve from the top easy and see down into the top of the plunger/barrel?
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Old 11-02-2017, 01:53:29 PM
John Deere 123 John Deere 123 is offline
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Default Re: Onan DJE Running Away

Ill look and see
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Old 11-02-2017, 01:54:25 PM
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Default Re: Onan DJE Running Away

Thinking about safety , what would you use. Is there a special glove to protect yourself while working on it pressurized. I'm guessing if it can cut thru skin it likely can cut thru a regular glove.
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