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An alternator/generator will produce large voltage spikes if the connection to the battery is interrupted (=bad connections). It is know as a "load dump" when this occurs and the voltage can easily be in excess of 100 volts.

Hi Kenny, yes the fuel consumption is up there, but depends on the load.

Welcome to the site! My 10kw genset is part of the xm757 project, but has been temporarily removed from the truck after generator head failure. The conversion to 12 VDC on yours probably only involves the starter motor, since the generator/regulator is an integral part of the 4a084 engine and...

The flasher unit is relatively easy to bench test. You have three connections to make, wire marked "B" to 24 volts, wire marked "C" to ground (note that the flasher unit housing is not grounded) and wire marked "A" to a grounded light bulb.

Voltage readings appear close to normal... Check and clean your battery connections and as long as the batteries are fully charged 2-3 years is far from an aging battery. Now, if they have been sitting at less than full charge, replace them.

Intuitively I'm thinking there is something wrong with multiple grounds, say if the house becomes grounded via the puny ground rod by the van exclusively for some reason, but I'll check into the facts and come back to you.

You need to identify (by wire number) what you have. From the diagram, trace the individual wires and label them and go from there.

The 1969 5-ton xm757 came with a dual tank system. There were selector valves and a relay for the fuel gauge to indicate level in the tank that was selected..

When using a grounding rod, you may want to drive it at an angle so that it can be pulled out using the vehicle when leaving. Don't use a ground rod when hooked up to the utility co service, one or the other, not both.

Didn't think they had hills in Florida:confused:

The grinding sound may be your starter pinion gear not engaging as you stated, caused by trying to start the engine with low batteries or poor battery connections. Sooner or later this will result (image): You may need to replace the starter motor. Do not bypass the starter relay, it's there...

Copy that.

Mike, Patrick (OPCOM) is selling his gear, it may be something there for you...

Lights? I got lights, this was my solution (added wiring to tap into existing circuits).

Reduces the stress on the individual batteries, they will last longer. Reserve capacity...

Sounds normal, but if it smokes after warmup then you may have a problem, dirty air filter etc.

Working on a radio install off and on. The PRC77 was used from time to to time, perhaps not installed the way I have it, but I like projects...

The multifuel was designed to military spec and based on a 1950 something German patent (hypercycle). The viscosity compensator was patented by Continental in the early '60s and provides the same power output regardless of the fuel used as long as the recommended fuels were used. The...

Any self respecting repair kit should come with a list of its content, I know mine did, but that was 12 years ago. Got it from Memphis. Here is a picture that I believe applies (from your description). It is possible that the parts of the slave cylinder simply stick from non-use and lack of...

Reads like clogged fuel filters, when did you change them last? All three, don't forget the primary below the generator/alternator.