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Help!

John Deere Tier 4 Engine, model 3029HFG30-EWX in a "Marathon" generator model MMG55 supplied by Generac

We're running a scientific campaign in Argentina for another six weeks, and our generator is plugging up its exhaust and now will only work in "limp mode".

Soot content is at 178% due to lack of clean #2 diesel fuel available. We've been loosing percentage each time we regen, moving us backward not forward.

Once we get this thing cleaned out, the plan is to burn Jet-A with a diesel fuel conditioner (so we don't burn up the injector pump), should be a much cleaner fuel to burn. We have documentation from the tech department of RDO saying we can do this.

Ok, here's what we need help with. We can physically clean the soot filter, but the computer thinks it's still plugged. Is there a way to defeat the emissions on this? All we need to do is clean out the soot filter, then tell the computer it's clean. Can we just jumper the diff press sensor, or something like that? Thanks!
 

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Help!

John Deere Tier 4 Engine, model 3029HFG30-EWX in a "Marathon" generator model MMG55 supplied by Generac

We're running a scientific campaign in Argentina for another six weeks, and our generator is plugging up its exhaust and now will only work in "limp mode".

Soot content is at 178% due to lack of clean #2 diesel fuel available. We've been loosing percentage each time we regen, moving us backward not forward.

Once we get this thing cleaned out, the plan is to burn Jet-A with a diesel fuel conditioner (so we don't burn up the injector pump), should be a much cleaner fuel to burn. We have documentation from the tech department of RDO saying we can do this.

Ok, here's what we need help with. We can physically clean the soot filter, but the computer thinks it's still plugged. Is there a way to defeat the emissions on this? All we need to do is clean out the soot filter, then tell the computer it's clean. Can we just jumper the diff press sensor, or something like that? Thanks!
I'm afraid you might need a tech and a computer to reset the computer. I hope someone has a solution but JD and other manufacturers have been very, very unwilling to admit to anything regarding emissions.

Treefarmer
 

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Are you sure it is not a problem with your specific unit. It just seems that there would be problems with other equipment and pickup manufacturers if the fuel was this bad?:dunno:
 

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I agree with Treefarmer, probably need a tech and computer to reset and perform the regen. Sometimes the dpf will get so plugged up and you can't regen it and have to replace it, have run into that on diesel trucks at work.
 

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Some countries around the world are known to not have good quality fuel and you may have found one of them. I would suggest you drain out that fuel and get some good fuel from a reliable source. It might let you run enough to get a regen. You might also try a "parked" regen as explained in the manual. I have never had to do that. Usually the regens happen more often if the usage is at low RPM's. A generator should be running at high RPM's, and would be less likely to need regens.

Dave
 

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Thanks for the responses. This is a very new generator, and has been a gigantic headache. Booo with these exhaust cleaning systems. The first issue we had was we did not do a good break-in cycle with it, so we had problems here with it sooting up. We think we fixed that by having the john deere guy come out and reset the computer while we did the proper break-in cycle using heaters and air conditioners to put a load on it. Break-in cycle complete, it was good to go for our 8 week science campaign in Argentina.

Our guys down there think there was something lost in the translation and they got grade 3 diesel, or the stuff ships use. We figure that was a big part of our problems but the tech guys say that the 50-60 hrs that the generator has run is not long enough to plug up our filter system, but yet it is again at 178%. Cleaner fuel can be had, and they think they're good on that but still need to have a john deere tech out there to re-set the computer.

Everything is difficult to obtain down there, and difficult to communicate to locals what is needed.

Still would love to hear a why to trick this computer into thinking the filter is clean, and maybe just run with it removed...

John Deere tech should be out tomorrow, hopefully they can get the computer re-set and the generator running again.

We would just rent a local generator, but most are only 50 hz down there, we need 60 hz. There is word of one available in a town several hours away, so we're working on that as a backup plan.
 

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I would ask the tech about the possibility of a sensor failure as well.
I take it the generator should run at a specific rpm to control the frequency (60 htz)?
Maybe possible to add a mechanical load to the engine to keep the exhaust heat up during periods of low kva use?
Also ask about the possibility of blending with kerosene if that is available.
Just how big is this generator?
 

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Maybe you could cut the DPF out of the system, dismount it and then soak it in diesel for a few hours and try to scrape the crud out? Then just reinstall with some band clamps and hook up the other connections.
 

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John Deere guy down in Argentina has been working on it yesterday and today. Last I heard, yesterday he got the percentage plugged down to 150%, from 179%. I asked my guys to ask about replacing some of those sensors as precautionary in case there are any failures happening there. Will see how it goes today..
 

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Update-clean fuel found

I don't know if anyone is interested, but I'm down here in Argentina now, and have relieved our other aircraft mechanic. The generator did indeed have a full dose of low-grade high sulfur diesel-a full 110 gallons of it. Instead of draining it they decided to burn through it and dilute it with low sulfur fuel. That was quite a headache of a decision for the previous mechanic, but seems to be working ok now. The exhaust resides between about 115% and 130%. Hoping it continues to go down as it runs its own re-gen cycles. Lesson learned: When you go to a foreign country with your tier 3 diesel, pay sharp attention to where that diesel is coming from.

Thanks for your ideas on this, I was hoping for the scoop on how to disable all the exhaust emission stuff on this thing but I guess they design it so it's not easily defeated.
 

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The update is appreciated, it’s very nice to have closure on things like this!


I was hoping for the scoop on how to disable all the exhaust emission stuff on this thing but I guess they design it so it's not easily defeated.
You can say that again....
 

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New problem-making oil

Newest problem in same generator.

Exhaust system seems fine, holding steady anyway.

But it's making oil. It has to be diesel, because coolant level stays the same. 650 hours on this gen-set. Initial improper break-in period due to under-load. We did another break-in, 100 hrs using the recommended method, with a John Deere rep in-and-out throughout process. Just started making oil though. Ideas on what could be the problem?
 

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Tricking the computer into thinking the filter is not clogged probably not the best option IMHO. Because, the filter is truly clogged.
Commencing a manual regen would be the way to go if the tech and the system allows it. As mentioned, removing the filter and burning it off or baking might work. Don't know if there are upstream and downstream sensors, or how the flow/blockage is determined?

Betting all these little diesels don't produce half the pollution of one Calif Forest fire?

You say making oil? Oil running down the side of the engine? Oil blowing out of the exhaust?
Smell Diesel on the dipstick or filler cap? Volume in the engine pan going up?
 
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