Micro CoGen.

Yes, it was absolutely the valve retainer on the end of the pump that caused the problem. When I opened the pump, the valve, spring and crush washer came out. When I put them back in, it seems that I lost the compression needed to seal the pump cylinder which is sealed purely by compression between polished steel parts and the crush washer at the other end.

As such, the lift pump produced enough fuel pressure to fill the high pressure chamber on ever stroke no mater where the fuel rack was located. Therefore, the engine ran at full speed all the time.

E.M.D.W.

Mike,

I installed the new pump and injector yesterday and reinstalled the genset today and then crossed my fingers.

Good news! She is purrrring nicely...well as nicely as a single piston diesel will purr eh ;-)

Thanks for your time and effort helping me out...if nothing else it is nice to have someone to bounce ideas off.

Ken

Yeah, it is a NextGen 3.5kw...my new pump should be here today.

Did you happen to notice if the governor lever was all the way to the right (away from the engine)?

Mike,

Wow, that would be more than I could ever ask...but if you are willing to do it, it will help tremendously!

My Kubota is driving my 3.5kw genset on my sailboat here in Fiji. My wife and I sailed here from Los Angeles.

Thanks again!

Ken

Thanks again for the reply! Any and all ideas are welcome and I enjoy the interaction with knowledgable people...especially while being here in Fiji.

I've had the pump out and open and the rack seems to rotate just fine. I've even had the engine running and used my finger through the oil fill to push the governor lever all he way over to the kill position without effect.

My conclusion is that the lift pump is filling the injection pump cylinder full on every stroke because somehow the metal to metal seals are not working since I opened them. Maybe the crush washer needs to be replaced or the torque is incorrect etc.

What I do know is that the injection pump is working to send fuel to the injector...it is just sending far too much and the rack does not control the amount. If I shut the fuel supply to the injection pump, the engine slowly stops.

Keep in mind I am in Fiji and they simply do not have test equipment here to test the pump or the injector. In the meantime I have ordered a new pump and injector from the states and they are now coming via Fedex at great expense.

I'm still wondering if anyone can answer my orginal question regarding the position of the slot in the governor lever???

The reason I'm asking this question is that my EA300 runs at full throttle and I can't control it with the speed control lever.

When I was removing the high pressure line from the fuel pump, I accidently opened the end of the injection pump aka the deliver valve holder. When I did this, the valve fell out together with the spring, crush washer and cylinder. I put everything together according to the service manual, however the engine only runs at full speed now. (service manual page M-41)

Have I screwed up the pump?

Thanks for the reply.

However, I fully understand how the mechanism works. What I am looking for is an answer to the alignment of the slot when the pump is removed and the engine is not running.

Does it look like the picture??? Is the slot essentially aligned with the opening. The service manual makes it sound as though it should not be, however the service manual tends to describe two different versions of the engine in the same graphic(page M53) (EA300 and EA400) which gets truly confusing since the mechanisms are slightly different in how they interact with the speed control lever.

I'm hoping someone has had there intection pump out of their EA300 and can tell me where the governor lever resides while at rest as this will answer some other questions I have not yet asked.

Thanks again in advance!

Thank you for your reply RS!

The info I need is not in the shop manual. I need to know where the slot in the governor lever is located when the engine is at rest.

Below is a picture showing where mine lines-up.

The reason I ask this question is that the position shown is essentially the full throttle position (full right in the picture) which seems odd to me. I would expect the at rest position of the governor lever to be somewhere to the left.

Can anyone provide insight?

Hello All who read...

My name is Ken and I'm located in Fiji trying to fix a Kubota EA300 genset.
I need a few questions answered that I can't answer using the shop manual.

When the injection pump is removed, where is the slot in the governor lever located while not running?