803 Bogs Down and dies at 85% Load

[USAMilRet]

http://www.powerspareparts.com/sear...a-fuel-stop-solenoid-sa-3865-5945-01-378-7172

For your fuel cutoff solenoid.

If he truly rebuilt the motor, you should have a higher oil pressure than 20-22psi. Should be around 60psi. You may want to take the oil fill cap off while its running to see if its pushing a lot of oil out of there. You will have a little spray coming out from pressure but it shouldn't be bad. If it is bad, then most likely the rings are not set right or a piston ring has broken. The rings have to be installed a certain way and they have to be staggered where they come together.

I agree on the oil pressure. Isn't the oil pressure adjusted by the relief valve on your the oil pump? No oil being pushed out when cap is off no large splatters either. Small amount of pressure coming out from the oil fill cap when removed. I see that about the rings.....common placement on all rebuilds. Stagger the first ring 45 deg from the piston sleeve pin then 45 deg more for second ring then repeat for third ring. I have no reason to believe that Scott did not know this.

Same source I found. From China. That $25 shipping DHL/FED EX shipping fee is a killer. Still about $20 to $60 less than anywhere else. Of course there is that odd site that wants $386 for it..........

 

[justacitizen]

low oil pressure could be caused bu clogged intake screen or foaming oil also

 

[USAMilRet]

I have decided to remove the crankcase cover for a look see. I want to know why I lost all that oil pressure or better yet, why I did not have a higher oil pressure to begin with.

 

[USAMilRet]

Well this should dispell any doubts that the lower end was rebuilt. You do not get components this clean with hundreds or thousands of hours on the machine.

After I removed the crankcase cover, I emptied all the oil that was remaining by removing the plug and using a small brush, brushed out the remaining oil that was in the bottom of the engine case. An examination of the oil indicates no water, fuel, or other contanaments that I could see. There were no metal particales in the oil or in the bottom of the engine case.

Here are some pictures of the insides as best I could get them. Everything looks new and clean. Not saying the rings are aligned right but this engine has cleary been rebuilt recently so there is no reason not to believe that the lower end was not rebuild in Dec 17 as indicated on the engine.

 

[USAMilRet]

More pics:

 

[USAMilRet]

And more pics...




Also, the numbers match the numbers of the generator, engine, and serial number on the data plate of the pictures sent to me last year by the rebuilder/seller.

 

[USAMilRet]

So with all this information (thousands of words in pictures, right?) why did I loose my oil pressure and why was it never over 20-22psi since I got it?

Is there a way to adjust the oil pressure by adjusting the relief valve? Is this even possible?

 

[DieselAddict]

Since you have the side plate off you should check the oil pump bypass valve. If its stuck open that could account for the low oil pressure.

 

[USAMilRet]

Oil pump bypass valve? Got to find info on that.

 

[USAMilRet]

There was no measurable vacuum or pressure coming from the crankcase.

 

[Zed254]

Fig 3-17 in ARMY TM 9-2815-253-24 shows oil pump relief valve.

 

[DieselAddict]

Fig 3-17 in ARMY TM 9-2815-253-24 shows oil pump relief valve.

Thanks. I'm at the office right now and can't check out the manuals.

 

[Zed254]

This may be a picture of the relief valve:

 

[USAMilRet]

There was no measurable vacuum or pressure coming from the crankcase.

 

[USAMilRet]

That's what I thought it was. Did not know it was the bypass as well.

 

[USAMilRet]

Anybody know what this is? Came out when I took off the sump. Looks like a restrictor to stem the flow of oil ro the pump. Not in the referenced diagram.

 

[USAMilRet]

Here is the oil relief valve. Under air pressure, it releases at about 7 psi. The book says fluid not air for testing (I have no fluid pressure tester) and that the pressure should be 46 to 57 psi. Took it apart, cleaned it, and now to figure the adjustment process. More spring pressure will increase the pressure dam.




Pictures from the crankcase side into the oil pump from strainer, and from pressure relief side. Teeth seem to look good.

 

[USAMilRet]

Anyone want to tell me what they think this is? I cant find it in the oil pump diagram in the 24P.

It was in the oil pick up tube at the oil pump.



EDIT: My Homer moment............nothing to do with the oil pickup tube except to where it is bolted to the crankcase.

 

[Zed254]

I've been looking, too. Cannot find any document references to it. We need someone to chime in who has experience with these parts.....

 

[jamawieb]

It's a spacer that goes on the bolt that holds the sump in place. If you look at your photos before you took it off, you can see it on the bolt, that it mounted right above the sump (holding it in place).