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How did the top end and the valves look? Some ideas for what to do next - (possibly not the best, but easy to do without any special tools): Set the piston at midpoint, and pour in 1/2 inch of diesel fuel. Then move the piston up and down by turning the flywheel to see if the diesel leaks past...

The pump should start at 23.6 volts. Do you have variable power supply you can use to test the pump. To me it sound like the pump may be the problem. Do you have another pump to compare it with, and compare the starting voltage, and current?

Just thought of another thing to try before tearing anything apart. You have fuel, and air, but not enough heat to light off the fuel. Try heating the cylinder and air intake with a heat gun or hair drier, to the point that they are uncomfortable to touch, then, while blowing hot air into the...

Don't let that stop you. You currently have an engine that does not work. If you are careful when you disassemble it, you can't make it any worse. Taking the head off is the first and easiest step. Take plenty of pictures when working on it, that way you have something to look at when...

I would take off the valve cover, and check the valve clearances before tearing the engine apart. Thats only two bolts. Maybe a valve is stuck open. Just be careful not to damage the gasket when you pull the cover off.

I use the Kat's brand; It's a good brand, but there are also others. I use a 250 watt unit on my hummer oil pan (2 gallons). Never have an issue starting it in cold weather, but the lowest I have seen here, north of Flagstaff is about 0F. If you get the pad style, make sure you follow the...

You can also pull off the fuel return line at the tank and point it into the tank fill opening (you might have to add a short piece of hose). See if fuel comes out, but stops flowing when the machine starts to droop. Then you will know if its a fuel delivery problem. Any chance the pump is...

The 2870 will output 70 amps, before it will safely shut down on overload. I have never measured my 802a starting current, but it might be enough to get it started since it is a small engine. Not sure about the larger 804A. (Has anyone here measured the starting current on an 802a while cranking?)

Since 3 phase works good, it is not a generator problem. Did this generator ever work correctly on single phase? Sounds like a wiring or switch problem. Based on how single phase is derived, it could be that one of the windings is reversed or disconnected when the switch is set to single phase...

I store my diesel in MFC's, with Biobor and PRI-D added. I usually rotate the fuel at 5 year intervals, although I tested one by keeping it 9 years, with no problems. Water, heat, oxygen, and certain metals are the enemy of diesel (and other fuel as well). Open tanks that can breath are the...

How do you know that the generator is the problem, and not the air conditioner? I spent hours trouble shooting a motor starter / motor circuit once, only to find out the device connected to the motor had mechanical issues, causing the starting overload. Can you connect another large load /...

Ignore my previous message. I read 831, not 813. Should have looked at the posted TM number.

No sealant is used on the headgasket. Just make sure all your surfaces and gasket are absolutely clean, then evenly torque the cylinder nuts. I don't like to go directly to the final torque. I usually go to 15 ft/lbs first, then to the final torque (same as the Yanmar manual).

Do you have compression? Can you hear the starter motor bog down on the compression stroke, or does it just whine like it's turning easy? Can you feel air blowing out the exhaust while cranking? If so, can you smell raw diesel? Is the fuel good?

Run your engine with the discs off to see if the RPM comes up. It won't hurt the machine to run without the discs.

Since both gauges are not working, there is a possibility that the set is wired wrong, or has been "re-wired". Check your voltmeters with a power supply, or a 9 volt battery to se if they work. Don't check the load gauge with a battery or power supply. That gauge has a 50mv full scale...

I use a surplus Fostoria industrial heater just like this one - Surplus Fostoria FES-1524-1A Space Heater (Not sure if I can post the complete link, but this one is on GovPlanet right now). This is a 15kw 240v single phase heater. The heater consists of six 2500 watt heating elements...

If it is the round filter mounting plate that attaches to the air preheater, you can just get a piece of eighth inch aluminum and make your own. It doesn't even have to be perfectly round. Drill enough holes for the engine to get enough air, and leave a strip of metal across the center to attach...

You will also need an upstream regulator on the cylinder, to drop the pressure to a level acceptable to the purge regulator. The purge regulator most likely cannot handle the 2200 psi from the cylinder directly.