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Humm, very interesting. Since I'm not familiar can you explain what we're seeing on the graph? Is this a 1 day time frame? Green is solar production throughout the day I assume?? What's the red, Net usage?

That slave port assembly looks correct just based off the pic. Ground cable looks to be about the right length... Out of curiosity did the one on the machine look like someone had modified it to make the ground reach to the starter?

Acetone / Lacquer thinner....

Normally the low fuel float will shut you down before running dry, but if it is stuck and the machine runs dry nothing will get damaged. Fill the fuel, then run the pump on prime/run for a while and it should re-prime it and push any air back to the tank allowing it to restart.

Unless I'm missing it, the TM's seem to be terrible as far as showing the battery and slave port cable routings, but without looking at one of mine, I believe the slave port negative goes to the back of the ground stud on the frame just behind and left of the slave port. Then another separat...

So in the picture up above the hoses are incorrectly looped together. Normally the line from the nipple at the cap goes to the bottom of the bottle. The overflow line at the top of the bottle gets connected to both the drain on the front of the block under the water pump, the drain on the bottom...

I'd be curious to hear the results.... The OP's issue definitely sounds like a float issue, but I'm also curious about the tiger loop scenario. I'm curious to see how a tiger loop works when fed with a pump. I put a tiger loop on my boiler but it is suction fed from the burner pump, not force...

Agree with LITD, fix the alternator and keep the battery charger as the backup. Radiator is a good old brass tank and everything is soldered to it. If you still have the nipple it should fit snugly into the hole in the radiator. If you have a propane torch, flux and solder you can fix it easily...

To R&R the pump, the only gasket in question is an o-ring sealing the pump body to the block. Usually the o-ring can be reused in a pinch. Worst case you can just add a bead of gasket sealer to the o-ring. On a PSU pump if the plunger shaft is broken you will know it as soon as you remove it and...

You can rotate the motor either direction if you are trying to get back to PC mark. If you are unsure about being at #1 compression, you can look inside the opening for the IP. The valve lobe to the right of center is the #1 intake. If you look through the IP hold that cam lobe should be...

By "Ring" I assume you mean the tip of the solenoid plunger? Lift or pry that up with a screwdriver to hold it out of your way. Does the lever coming out of the side of the IP ( with the linkage rod attached to it move freely up and down, or is it sticking? It's impossible to say for sure what...

Here it is. https://www.steelsoldiers.com/threads/mep-802a-alternator-repair.215258/

Don't be afraid of the linkage, just lift up on the ring at the tip of the solenoid plunger, it's just pushing down on the linkage lever coming out of the IP. Then you can move the lever right where it comes out of the pump. You will not hear or feel anything when turning the motor over as far...

Correct, there are tons of threads on here about that alternator. Search for and read-up. Then take the PN's for the alternator and search the web. @Light in the Dark also recently posted the name of a company he has used previously to rebuild these alternators.

Just sent you a PM.

Well, as CB said, there is no reason to give up until you see where you're at. To tell you the truth, 20 year old fuel is better than 4 year old fuel because of the recent Low Sulfur non-sense, but 20 years is a long time. Start by moving the fuel lever, if it moves freely you have 2 options...

The main issue with the 002 is similar to your JD tractor incident. If the old fuel has gummed up the injection pump and the center plunger is stuck, rotating the engine can either break the plunger guide ( on an Ambac M50 pump ) which acts like a shear pin to protect the pump from damage, or...

If you could send us some detailed pictures of the machine, that would help a lot. Especially take pictures of the AC reconnection box and take the side cover off and take pictures inside the AC box. Point the camera upward to get a picture of the underside of the L1 L2 L3 L0 lugs. I would...

Humm interesting... that one is also rated at 500 CCA. Most of the automotive 51R ( used in just about every Honda out there ) I have always used were rated at 550 where Group 51 ( opposite +/- post orientation ) were 500, for some unknown reason. Regardless, 500 CCA is PLENTY for that machine...

Also consider fuel consumption. the 803 will be way more economical than a 15kw or 30kw. However you are right that you may encounter an issue if your hot water tank is heating, your wife is making coffee and heating up a muffin in the microwave, and the AC kicks on! Slight load management may...