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803a dies above 75%

Hello everyone,

I've followed lots of information found here and online. My 803 has 2 new IPs and two older ones. I took the advice and utilized heaters to provide a load. Initially 2 heaters would only give 10k watts max which the genset had no issues. I recently found a 7500 (6250 on low) model and added it to one of the original heaters.
Problem:
6250 + 4000= 10250 - no issue
Add 1k more and the genset throttles down and won't recover even when removing the load.

7500 + 3000= same, throttles down quickly

I've even tried increasing throttle before adding the 2ng heater, appears dies slower but still same result.

Injection pumps are set all the way counter clockwise (less fuel?).

Could that be my issue or is there another problem?

I've seen others test at 100 and even higher, I'm trying to do the same in preparation of a real need.


Thank you in advance
 

Jeepadict

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This seems to be a popular subject over the last year, tho at various power levels. The solution seems to be eventually found in the mechanical governor behind the front engine cover getting caught/hung up by either being bent or corroded.

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m32825

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Mine handled 14.4kw for a couple minutes recently while load testing. That would be 60A per leg.

When I first got it, it would die under load. The problem was a weak fuel pump, it was getting starved when demand increased. I wonder if part of your temperature difference is because that leftmost cylinder is getting less fuel than the others?

-- Carl
 

m32825

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Howju dew dat??

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See this thread:
 

Jeepadict

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See this thread:
Very cool!!

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m32825

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@Rellierell 803a, here's my pump pressure thread:

 
Update: replaced fuel filter and it's better. Handles load changes better. ONLY stalls when going from 11,500 to 12,500w. Much better than before.

I also found fuel bowl missing spring. So in the hunt for that. Then change the fuel seperator. Then I'll go from there.

Lastly I'm going to swap that 1st injector pump.
 

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FarmingSmallKubota

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Update: replaced fuel filter and it's better. Handles load changes better. ONLY stalls when going from 11,500 to 12,500w. Much better than before.

I also found fuel bowl missing spring. So in the hunt for that. Then change the fuel seperator. Then I'll go from there.

Lastly I'm going to swap that 1st injector pump.
Did you have Algae in the fuel or what did it look like? have you changed it before?
 
So I've only had it a couple months and THOUGHT they were changed out

The first picture is the fuel filter, plenty of water and not much liquid came out.

It ran better as I posted.

Then the water seperator came in today and I swapped it. Notice light watery fluid as well.

The right can which is more red is after il flushed some diesel through the new seperator.

*red is from my adding trans fluid to the tank a month ago. Old diesel technician taught me trans fluid is a detergent.

I'm waiting from the spring from the fuel filter to arrive before firing it up.
 

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