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After studdying the TM exploded view i realized that the fuel rack was over throwing and loosing the injection pump metering rod. After much trial and error and one failure to shutdown the unit runs. Im prety sure the fuel rail/linkage is worn. Now the only problem is it struggles with a...

I have disconnected the solenoid and moved the rack with the injection pumps out and it intermittently dosnt move the rack. Im thinking its the linkage internally.

Well i was able to diagnos the injection pumps as being good. My issue is the fuel rail feels like its not completly attached to the shut off solenoid. It some times catches and moves the rail and some times dosnt. Guess my front cover is coming off?

Spot on guyfang, thank you. The ossolating was due to a crack in the return line covered by the cloth. God i hate that stuff. The other one that dosnt start i have narrowed down to the check valves on the IP. With out them i get fuel flow. With them nothing. I took one appart and clean/oiled...

Yes i did. I replaced most of the 3.5mm return lines. I will double check them and hardlines tomorrow.

Just cracked the lines ontop. It helped initially then i shut it down to put the muffler back on and the ossolating came back. Tryed with the muffer off again and its still ossolating.

Its a long and slow. Really slow when under load. Should i crack the hard lines at the injectors so see if its air?

Yes i cracked that line. I totaly removes the radiator side hard line and im getting nothing, i have fuel at the IP soft line. I can feel the fuel rack engaged on the IP pin.

Any idea what would cause an 802a to ossolate? Even with no load, really bogs down and almost shuts off with a 5kw load. This is for a different gen set.

Yes i blew into the line off the last T above the head and its clear.

Fuel filters changed and cut open to check. They were clean and now new. Getting fuel out of every soft line. I am not getting fuel out of the injection pumps. But i am getting fuel to there soft line. I pulled one and the plunger in the engine is moving up and down when i crank it. Do these...

I just got the gen set a few days ago and only saw it run for about half an hour. It would make sence that its a blockage but like you said thats prety far up in the fuel system. Guess its time to pull the cover, fuel lines, filters.

I will check that tomorrow. Thank you. Its a real tight place to be working ontop of that head.

Im getting alot of fuel at the hard line out of the canister filter. I cracked the banjo bolt loose thats towards the rad. That is the output right? Its almost like its got a air bubble in the fuel system. Im going to try and get a wench on the hard lines ontop of the head tomorrow.

Just got a mep802a primed its fuel system and started load testing/burning the wet stack off. Shut it down after half hr to add more load. Then it started running and shutting off. Running less and less until now it dosnt start. Fuel is at 1/4 tank and puckup is covered. I get fuel out of...