803a dies above 75%

[Rellierell 803a]

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

 

[Rellierell 803a]

Left to right temp readings

 

[Rellierell 803a]

Amp draw pics. I think it's overloaded and that's the issue. Should have stuck with 3 smaller heaters.

Each leg
11.5/ 28.4= 39.9 per

 

[Jeepadict]

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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[Light in the Dark]

If its happy at 10, let it run loaded for an hour or two there. Put some seafoam in it at the same time... Really make the unit work, and clean everything up. After that, test with additional load as needed. But remember not all load is equal.

 

[Light in the Dark]

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

The IP hoses should be as close to touching the vertical push rod tubes as possible... And identically positioned across all cylinders.

 

[Rellierell 803a]

The IP hoses should be as close to touching the vertical push rod tubes as possible... And identically positioned across all cylinders.

Perfect. That is where they all are positioned. Thanks

 

[m32825]

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

 

[Rellierell 803a]

Thank you. Will you elaborate on what you used (setup) to equal such a load?

 

[m32825]

Thank you. Will you elaborate on what you used (setup) to equal such a load?

MEP-803a load testing

A little post hurricane Milton load testing to wring things out. -- Carl

steelsoldiers.com

 

[m32825]

Screenshot from the peak of that test

 

[Jeepadict]

Screenshot from the peak of that test

View attachment 935313

Howju dew dat??

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[m32825]

Howju dew dat??

Sent from my SM-G970U using Tapatalk

See this thread:

IoTaWatt WiFi electricity monitor on MEP-803a

I am running the house on the generator to burn fuel from this year's hurricane season. It's a good practice run for everyone, helping us figure out what we can combine and find any issues. I wanted a way to monitor usage without having to go out and look at the load meter so I ordered an...

steelsoldiers.com

 

[Jeepadict]

See this thread:

IoTaWatt WiFi electricity monitor on MEP-803a

I am running the house on the generator to burn fuel from this year's hurricane season. It's a good practice run for everyone, helping us figure out what we can combine and find any issues. I wanted a way to monitor usage without having to go out and look at the load meter so I ordered an...

steelsoldiers.com

Very cool!!

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[m32825]

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

MEP-803a : AirTex fuel pump substitution

My 803 had a Facet 40193 primary fuel pump installed in it. I was having problems with it dragging down and shutting off after brief periods of load testing. I could not find the recommended AirTex E1074 anywhere. Replacement Facet pumps were over $200, that didn't seem like a good choice given...

www.steelsoldiers.com

 

[Rellierell 803a]

MEP-803a load testing

A little post hurricane Milton load testing to wring things out. -- Carl

steelsoldiers.com

Thank you. Question do you know what amperage you were pulling per leg?

 

[m32825]

Thank you. Question do you know what amperage you were pulling per leg?

Current transformers on L1 and L3

 

[Rellierell 803a]

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.

 

[FarmingSmallKubota]

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?

 

[Rellierell 803a]

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.