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Oh boy... that's not the easiest repair to make. The timing cover has to come off to take the fuel lever off and replace the o-ring. The lever is 2 pieces that you have to separate in order to pull it out. You have to remove bolt #18

Some smoke at 105% load is not uncommon. I'm actually surprised that only one cyl is smoking. My first thought is either metering pump timing or metering pump flow adjustment slight off on that cyl. You could check cyl. temps on a 4 cylinders and see if the smoker is hotter than the rest and...

Given the recent issues I've seen with low sulfur fuel and IP pump problems on 002's and 003's I've switched from the diesel additives found at the local parts stores ( Howes, Diesel 911, Power Service ) to Optilube XPD exclusively. I also add in a bit of ATF as well. Specifically for the...

Not sure what you mean by cut them out? The stencils are not intended to be printed and hand cut as they are not the correct font. The intention is to use the wording and spacing / alignment shown and purchase stencils from the company indicated using the size and military font listed in blue...

Looking at the starter I have a feeling someone threw in a starter with the incorrect number of teeth.

I'll have to get you some pictures. He was I think 11 when my older brother gave him a broken down 425 for parts. He rebuilt it, threw in one of my LPW2 engines and fabricated the entire front fork mount / hydraulic piston assembly as well as the rear 3 pt. fork setup. Also a 4 way custom built...

Case 580D 4x4 with bucket forks, or Lull 644 when plucking off or plopping onto trucks and trailers. My Son's JD 425 also has custom built fork attachments both front and rear and can pick up an 803 or 003 with either end. I've delivered several using a cheap 4x8 harbor freight tilt trailer...

Maybe try wet blasting to keep dust to a minimal. I've heard a lot of good things about that "Dustless Blasting" co., if anything is available in your area. I hear you can rent the equipment and blast it yourself. As for chemicals, only thing I have found is that taking the coarsest sanding...

Fuel pump! if you ask me....

I 2nd that notion! Something doesn't sound right to me. I'd first verify your gages are reading accurately when under heavy load. There's no reason your other items should be running "slow" if the generator is operating normally. Something else must be going on.

By chance is the seal still in the hole? I don't remember off hand but pretty sure there is supposed to be a seal in there. I don't think it is a flat copper washer like the 802/803 either.

This is what I was referring to. Picture doesn't look exact, but it's the only thing I can think of off hand that is close.

The TM should be available up top in the TM / generator section of this forum. The IP is pretty much identical to the pump in the 005. Looking at your picture, I think that might be the pressure regulating plunger and spring that goes inside the end cover where the fuel line attaches. Hard to...

Yup. sounds about right.. I was thinking around 76' but close enough. Be warned... the early Hollingsworth machines , 75' - 82'ish are the ones with the American Bosch IP's in them.... A Ticking time bomb if it's a machine that has been sitting a long time and you don't take the proper steps to...

With the bodywork straightened, now you can get the "normal" amount of oil drained out... not all of it by any means! The design of the drain line will leave well over 1/2qt. of old oil in the bottom of the block, probably closer to a 3/4qt. Tipping the gen towards the drain line can help some...

You have to remove the top cover , the rear cover where the tank is located and the entire radiator support assembly. It may sound difficult, but it really isn't hard at all. just have to be aware of a few hidden screws, mainly where the radiator support attaches to the 2 strips under the side...

That's a really clean engine! Lister Petter valve covers and all....

The strange thing I've seen many times is that the trailer mounted 802/803 units would often come with a section of drain hose and a right angle fitting in the tool box, but never installed on the machine. This is because along the way someone probably got their wires crossed and never realized...

Not really... the generator is pretty open in a few areas where any fuel that may have dripped in the top will drain out. You can spray through the opening with electrical cleaner if you want to be sure everything is rinsed out, but personally I wouldn't be too concerned. By now it will only be...

My understanding is that an 003 main breaker is a 100A magnetic breaker and the 002 is a 50A. My 003 doesn't like my 7.5hp air compressor, but it will start my 5 hp compressor. The magnetic breakers typically hate motor starts, but I am a bit surprised the soft start on your AC didn't help. I'm...