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While you had it running did you measure the DC voltage at the batteries? If you had the proper voltage at the batteries then they were charging like they are supposed to. The gauge itself will not shut it down, unless it drained all of the oil in the pan through the pressure gauge. The two...

You can attach a muffler, but it's not going to make much, if any difference. The set already had a muffler on it (inside of the shutter box that surrounds the exhaust pipes). The noise you are hearing is the diesel engine noise and not so much exhaust noise. Let us know how your test works...

The ground on the newer plastic ones still grounds through the mounting bracket and the faceplate of the panel. There is a grounding shunt (a braided cable) connected to the control box mounting frame and attached to the underside of your control panel that is probably the culprit in these...

OK, I'm not understanding the problem or question now. You replaced your "replacement" VR with another one and the smoking stopped. This tells me that the "replacement" VR was the problem causing the smoking. You are now getting 26 to 28 volts at the batteries when the set is running? If...

that part you are calling the resistor is actually a capacitor. And yes, it should be connected the VR red wire and the mounting screw. It sounds like the hook-up is correct and the capacitor should have nothing to do with the stator getting voltage from the batteries. Even if it were shorted...

sounds more to me like a faulty VR than the stator...at first. But now that your stator started letting the smoke out, you probably have both bad. If the stator was putting out 30 volts AC, then it was doing it's job just fine. Also, the stator needs no excitation voltage from the batteries...

You're not doing it any good, but since it's a mechanical engine, probably not. The fuel pumps might not like it too much though. I visual check of the stator probably isn't going to show up much, but it's worth a look. Since it makes it's voltage by magnets in the blower wheel passing by the...

You should be getting about 28 volts, give or take, at the battery terminals when the set is running. If the fuse is good for the DC charging system, and you replaced the DC VR with a known good one, you could have a bad stator winding behind the blower wheel. While these very rarely go bad...