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newer 803A smokes and bogs down with load ... start with injectors?

BA in CO

New member
13
11
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Location
Ault, CO
Advice on alternate sources for parts? I can find gaskets but nothing yet for rocker arm, push rod etc.
local Onan parts dealer wants a serial number that is one letter and 4 or 5 numbers? Sorry, silly questions but the easier i can make this for my mechanic the better off I’ll be ... thanks.
 

Ray70

Well-known member
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West greenwich/RI
Mayi Diesel ( Sales@MayiDiesel.com ) also on ebay has pushrods for about $18, they are also pretty easy to straighten yourself, if not mangled too bad. You can also ask them about a rocker arm, she told me they can get just about anything for those motors.
After reassembly, pay heed to the warnings in the manual about letting the motor sit ( before cranking ) after you tighten down the rocker arms. The lifters will expand out and if you crank before they collapse down you'll bend the pushrod again! ( ask how I know.... )
 

Daybreak

2 Star Admiral
Steel Soldiers Supporter
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Howdy


Do you have all the tech manuals?
TM____24P
NSN 2805-01-435-3890 ONAN ROCKER ARM ASSY Part 186-6094

 

BA in CO

New member
13
11
3
Location
Ault, CO
Long term follow up ... reminder 803 smoking and choking down at 50% load ... fuel tank dirty so cleaned and replaced tank, filters, injectors tested ok ... turned out to have broken rocker arm, bent push rod, popped hole in valve cover ... took a long time for the machine shop to work over the head (grind valves, replace guides, reface head)... HUGE thanks to Mayi Diesel for helping get all the parts needed. My mechanic got it all back together, manuals were very helpful even for a pro ... initial load test and the machine runs smooth. Smokes a little at 80% but not much, only see it against dark background ... I only got to 80 % load, need to add some more heater elements to my “load bank”

Revised ... when I read the gauge correctly hertz drop only 1.5 so within 3%. So far so good!

on on another note ... I also tested my 804, using just 2 legs for 120/208 ... it stays really smooth throughout load test. Well pump is the only motor I need and it’s specs are good down to 190v so well guy tells me it should be good ...

Many thanks to this Forum for your suggestions and support!
Al
 
Last edited:

USAMilRet

Member
390
15
18
Location
Tampa, Florida
Long term follow up ... reminder 803 smoking and choking down at 50% load ... fuel tank dirty so cleaned and replaced tank, filters, injectors tested ok ... turned out to have broken rocker arm, bent push rod, popped hole in valve cover ... took a long time for the machine shop to work over the head (grind valves, replace guides, reface head)... HUGE thanks to Mayi Diesel for helping get all the parts needed. My mechanic got it all back together, manuals were very helpful even for a pro ... initial load test and the machine runs smooth. Smokes a little at 80% but not much, only see it against dark background ... I only got to 80 % load, need to add some more heater elements to my “load bank”

Revised ... when I read the gauge correctly hertz drop only 1.5 so within 3%. So far so good!

on on another note ... I also tested my 804, using just 2 legs for 120/208 ... it stays really smooth throughout load test. Well pump is the only motor I need and it’s specs are good down to 190v so well guy tells me it should be good ...

Many thanks to this Forum for your suggestions and support!
Al
Wow....what are the odds. BTW was it the number 3 intake? I just overed lasr week that I have the same issue.
 
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