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I have some more in process but still a ways out. I'll post up when I get close and the paint is drying!

Per the manual, when you pull the pumps you must leave one pump in to keep the rack engaged. Otherwise the front of the motor may need to come apart to reset the rack. Also, the pumps rorate on serrated clamps. The rotation sets the fuel balance between pumps so each cylinder contributes...

Check out the big auction site for 24 volt pumps. There are several pretty cheap. On the 802a and 803A those pumps just push the fuel in a circle so the exact flow or pressure rating is not a big deal. Just get one that has that cube shape with the right connections and it should work fine...

Either your float switch is bad telling the controls that the fuel is too low or the magic box that the float switch is connected to is bad. You can run it in the battle mode which will bypass the shutdowns. The float switch can be pulled out and checked and adjusted if the float height is...

The hose ends should be 37 degree JIC -4 size. Any hose shop should be able to build a hose. Bring in the old one for them to copy. You might try using the hose from the aux pump to the top of the tank if you want to get it running. It's probably way too long but it should work as temporary. I...

Please report results. Thanks,

The shims set timing, and as you say must go back the way they came out and may be different on each cylinder. Fuel rate is controlled by rotating the pumps. The pumps should go back at the same angle of rotation as they came out. One pump must be left in at all times to keep the rack in...

The check valves have to be in the pump as they are not elsewhere. Not sure what they look like as I never had a pump apart. There are repair kits on the big auction site maybe they have pictures of the parts. Although often practiced, it is not advised to pour fuel into a filter housing due to...

I'm sure the hole has a purpose. To fill the system, I put my finger over the return in the tank and use a mighty vac on the bleed screw on the filter cover to draw fuel into the filter housing. Then it's only a few primer pumps to complete the process. Your pump might be air locked. If it...

I've never had one apart. (And I've got about 35 of these running in the last 2-1/2 years) They do leak backwards over time and loose prime. Some in a few hours others take weeks. With the cam lobe off the plunger it takes 250 - 400+ quick strokes of the lever to fill a dry filter and get air...

All these threads ever talk about is getting the two sets synchronized. If there is not a master and slave governor and a master and slave voltage regulator then it is hightly likely a voltage regulator will be smoked. Load is a function of fuel position and with mechanical governors and some...

Find this manual MARINE CORPS TECHNICAL MANUALARMY TECHNICAL MANUALTM 05926B/06509B-34/3TM 5-6115-615-34NAVY PUBLICATION NAVFAC P-8-646-34AIR FORCE TECHNICAL ORDER TO 35C2-3-386-32 And go to section 7-6 and start with #4 and follow all the steps in order until #12 is complete on page 7-8. If...

Just to confirm you are checking the circuit interrupter relay which is the big one under the top lid not in the box behind the gages. There is also a relay behind the gages that powers the big relay. check it too. Download the manual and see what it has to say. Chances are it will be a lot...

That solenoid stutter is a classic problem with several possible causes. first, before cranking the solenoid should snap on and stay on. Whether it stutters or not the engine will crank if the switch is turned. Battery connections are usually a problem, easy to clean. Make sure they are tight...

I never load banked a gas unit. I did load bank the 3kw diesel Pow'r Gards that you might see in the auctions from time to time. The weight of the gen end is less than half the 3kw 016 series. Their gen end is equal to a quality consumer unit like a Honda. The Pow'r Gards do not like...

I guess if one really wanted to have 12 volts it might be simplist to convert the starter and then add a 12 volt to 24 volt step up transformer and tie it into the existing 24 volt system. I believe there is only a few 24 volt wires coming off the battery connection on the starter that feed all...

I have a home made load bank that has enough steps that when I use the variable voltage control on the generators I can get almost complete variable load coverage from 450 watts to 15kw. It uses commercial duct heating elements. I don't test 002s but I do test 802As. At my elevation, around...

The entire low voltage controls are 24 volt. With the one exception that the glow plugs are 12 volt wired in series to use 24 volt as a pair. This unit has fuel level, oil pressure, temperature shutdowns and gages plus starter and alternator, two 24 volt electric fuel pumps, hourmeter, all...

The 004 is only a 3 phase machine. It can be reconfigured for single phase but requires reworking the gages for correct reading of load and reworking the breakers. Normally output is derated for this conversion but, possibly, there is enough beef in the windings to carry the same 15kw rating...

The dead crank switch is to turn over the engine only for prelubing or other service work. No fuel is turned on. dead crank will not start the engine. If you want to try starting it using the dead crank and bypassing the control panel then you need to power the electric fuel pump inside the...