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Question. What happens if you run it with no air filter? Next question. Do you have an air compressor? Next time you load test and it starts to stumble, start blasting some air into the filter housing (with filter in). Don't go nuts, just a steady low-force blow. Does it catch back up and stop...

Something else interesting I found, their style nickname is stovepipe. Search ebay for "dialight stovepipe".

This thing I found looks pretty damned close. I know your lens is clear, so this part number should hopefully send you down the right rabbit hole.

I've used this one a few times. It does the trick, and the price is right. I *believe* the factory switch is NC, and opens at 20psi (someone may have to correct me). This switch is NC/NO (3 terminal) 15psi. 5psi in this case, to me, is negligible. https://www.ebay.com/itm/354672471657

If you ever move towards a 48V system, I can't say enough good things about the EG4 Chargeverter.

I'm honestly not sure why that was done. Maybe one of the military guys can chime in. I do know that where it currently is, if the valve were at the fitting like the 803, there wouldn't be enough clearance to pull it out because you need to tip the tank upwards. What's also interesting is that...

While you're pulling the fuel tank, replace the two nitrile bulkhead fittings, pull and clean the contacts on the level sender, and completely clean the inside of the tank-- there's going to be a lot of rusty sandy gunk in there. Probably good measure to replace the fuel return line as well...

Does this also apply to the 831 units?

Without Kurt, my wife would be stuck with a bunch of diesel lawn sculptures. Instead, she's stuck with a bunch of generators.

Do you have pressure in the crankcase, or are you losing any coolant? You can make a manometer out of a flexible clear tube to stick in the dipstick while running. Compression test as recommended by another-- need to figure out what those cylinders are doing.

My overlord will not allow me to run the generator on a Sunday night, so I'll get on it tomorrow afternoon!

Have you tried adjusting the governor droop? The visible smoke is still slightly worrisome to me, as I never see it on units until approaching 100% load, and even then it's very light. Something is still telling me you have a fuel / air problem. I'm going to bump one of my generators on today...

You'll want to check the exhaust manifold itself, not the block. It's not an exact science, but there's a few spots you'll learn to hit at certain angles. The goal is to see what the exhaust gas temperatures of the cylinders are, which can start to tell you if you're starved for fuel or not...

While it's running, do you have an IR thermometer? I'd temp each cylinder's exhaust on the header and check if you have a large discrepancy between cylinders. It's possible that you have an IP stuck closed, or an injector clogged-- which is essentially a dead cylinder. Have you taken any of the...

While it's running, stick a manometer into the oil dipstick. You should be running with at least 1" WC of vacuum. This will tell you that you don't have any crankcase pressure, so the piston rings and gaskets are probably in good shape. I used this nice cheap one from Amazon. You can make one...

On the eternal list! A few days before this, I did the big PM. Fluids, filters, batteries, degrease / pressure wash, fuel lines, pulled out the tank for cleaning, replaced the bungs, and wired up the new VR and remote start. Yup! So the EG4 does the SOC monitoring and has a set of dry contacts...

A few updates on the project! The 803 was sold to a customer, and an 802 has taken its place. This works out well, because after talking with a few people, I'm going the EG4 Chargeverter route. This will allow me to run the generator at near 100% capacity when charging, which is a very good...

I ordered an "unbranded" brand from Aliexpress. Without getting too deep into the weeds, if you can find it on Alibaba / Aliexpress, it's the same product being sold domestically for 2X+ the price, with custom branding.

Batteries have arrived, now just need to find a few hours to hook it all up!

Thanks everyone for all the input on this thread! Passed my electrical inspection this morning, now just waiting for Eversource to come give me my net meter. Just about to hit 100kWh of production in the few days it's been hooked up and running. Can't wait to knock a few more trees down keep...