Perkins
Fuel Leak in Supply or Return System
Strong diesel fuel smell or visible fuel pooling under generator
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Safety Warning
This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.
If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.
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Possible Causes
Loose banjo bolts on fuel filter head, Cracked flexible fuel hose, Leaking injector leak‑off line, Corroded steel fuel pipe
How to Fix / Troubleshooting
Safety: Eliminate all ignition sources. Ventilate the area and contain spills with absorbent material.
- Trace leak: Wipe lines dry and observe while the lift pump runs or engine idles. Follow wet areas back to the source fitting.
- Tighten fittings: Carefully tighten banjo bolts and flare nuts on the Perkins fuel system. Do not overtighten and strip threads.
- Replace hoses: Swap out cracked or hardened rubber hoses with diesel‑rated hose and new clamps.
- Injector leak‑off: Replace brittle leak‑off hoses on the injector tops if they seep.
- Test after repair: Run the engine and recheck for leaks.
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Repair Difficulty
Medium
3/5
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