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Your stiff IP linkage means the IP is gummed up internally. Luckily it sounds like it is just gummy and you did not break the plunger guide by starting it up like that. Seafoam is a good idea, but could take some time. I personally would remove the fuel inlet line and pour Berryman's B-12 or...

I wouldn't think 30V would cause a problem for the fuel solenoid. The charging system is going to operate at 26-28V normally so I doubt the solenoid would be that sensitive to an extra 2V. It is an indication that your DC VR is going bad, but probably didn't kill the fuel solenoid.

Is the lockout needed to disconnect the solar from the batteries? Assumingly you can only have one or the other active at a time, unless you are feeding into some kind of phase synchronizing inverter to allow generator and solar simultaneously?

Actually the way it works is the governor solenoid is only there to KILL the IP, not to turn it on. Without the solenoid in place and with the engine off the fuel flow will be wide open. When the engine starts the governor will bring the fuel flow down in accordance with where the throttle lever...

NOS oil gages were available on ebay not long ago. It is possible that yours will work once you start it. Just because it isn't currently at zero doesn't mean it's totally frozen.

Yes, just push down on the linkage at the IP. That's all the solenoid does..... Just keep in mind that the solenoid also shuts the machine down in the event you loose oil pressure or overheat, so without the solenoid those 2 safeties are being bypassed, so keep an eye on it!

"With the HVAC running and the normal amount of lights turned on (it was about 8:30pm when he finished) and all the other things that normally run, the load was about 25%. Turning on the only two-phase load, the oven, took it to about 75%. Without the oven and just lights, clothes dryer (gas...

I'd rather have yours than the on I found.... yours fits better in a toolbox too...

The electrical box you have there is ( WAS... looks like to disassembled it ) a generator synchronizer, meant to switch the load from 1 generator to another while under power. Might be worth something to someone in the generator community? I see a slight hint of rust staining on the I beams, but...

:ROFLMAO: Cause' everyone's got a Kelvin Bridge or 2 in their tool box....;)

Agree with the 2 most likely failures on your current 803. As for the haze, a good running machine really shouldn't have any noticeable smoke when its running and warmed up unless you are in the 75%+ load range. You'll get a little smoke at start up, but it should clear up within a minute or 2...

When you reassembled the pump I assume you got the flat of the throttle lever pin to engage into the slot in the plunger sleeve? Sometimes it can be difficult, but 99% of the time the throttle control unit won't seat all the way unless the pin is engaged or the plunger sleeve is completely out...

This is the DC breaker you're talking about I assume? My suggestion is to 1 by 1 remove DC powered items until you find the issue. When first attempting to start, I assume you are able to fill the day tank with the electric fuel pump with no issue? if so, that probably eliminates the fuel pump...

Ok, thanks for the consolidated history. Regarding the shut-down event, it sounds more like coincidence than anything. There is Zero possibility that you opening the door to check the temp could have caused the temperature to rise enough to cause additional oil pressure loss. Since the pressure...

Yes! last couple years I have gotten ethanol free gas in upstate NY and VA, got about 25Gl each time, added stabilizer as soon as I got it home and worked great for yard equipment etc. No issue at all storing it for over a year. Have seen it in 91 octane and 87 depending on location.

Lets recap to make sure we're all on the same page. If I'm reading correctly you changed out your 7 year oil with fresh 15-40 and some STP treatment? This raised oil pressure slightly, up to about 25 psi. when hot. You sent off a sample of the y year old oil and it came back low viscosity...

One thing to check on the 802 / 803 is to take off the top cover and look carefully at the 12 leads coming off the generator going up to the terminal strip and to the AC select switch as well as the 3 fatter wires going from the AC select switch into the circuit interruptor. Make sure none of...

That's exactly correct. If you have trouble removing the injectors another way to open the valves is to remove the rocker arm nut on 1 valve per cyl. and put a few washers or a larger nut over the stud to act as a spacer then put the original nut back on and tighten it down until the valve is...

99% of the time it's a bad sender. In your case the fuel sender is bad. This is very common on these machines. The resistance should be 30 ohms full and 240 ohms. empty. 3000 ohms is why your gage is pegged. Best bet is to replace it with a 5.5" long WEMA stainless steel marine sender with a SAE...

Back to the glow plug thing.... an 802 doesn't have glow plugs. It only has pre-heaters in the intake manifold. Either remove the injector or take off the valve covers and hold a valve open ( this can be done you prying down on the valve tip ) while you turn the motor over by hand an see if any...