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What is the faint scratch on the side casting from near the right angle oil fitting on the block, along the path of your blue line? Scratch? Crack? What does it look like at the bottom side, especially near the gasket? If the fan blades are dirty or oily, I would suspect oil misting or fuel...

@jqc99 The photo of the engine looks nice and clean. Are you sure that this residue is oil, rather than diesel? E.g. are the return lines ok, and your tank doesn't weep diesel out of the drain fitting, or worse the tank itself? Is the oil filler cap on tightly with a functioning gasket? This...

Just for perspective I don't know about the 804, but the intake preheaters (aka glow plugs) on '803 can draw 70-100A when cold on start up. I believe that the Isuzu tip type glow plugs (01-360-3314) are closer to 25A total, but that's still a significant load on the batteries when the starter...

I guess that my #1 question is: What kind of thread sealant did you use? In general, yes, a rag can work ok, but it depends a bit on what you sealant used. My goal is always not to push any thread sealant or remains of thread sealant into the coolant area. If it is something like, say PTFE...

FWIW: that Yanmar bolt is available from a number of sources, both Yanmar, and open market. Try using the Yanmar part number, or "M6x40 safety wire bolt" In a pinch, you could use and m6x40 with an extra jam nut. For about $15, you can buy a jig for drilling the bolt head and a jig for...

That's quite the stable!

Perhaps two LEDs either side of CB1 to let the operator know that there is power and CB1 is closed?

Take care of those ribs! Good luck. All the best, 2Pbfeet

Perhaps a fuse and install it before the breaker for the convenience outlet so there isn't an accidental loss of signal? Loss of the AC signal mighty not be good. All the best, 2Pbfeet

I agree. I think that in my experience Generac seems to be pretty parsimonious in their designs, subject to longevity design limitations.

Love type W cable! It is great material. Good luck with storm! I'm not sure if that means grid or no grid for you. All the best, 2Pbfeet

Ask Generac?

Have you ever seen it run without black smoke? I.e. could an oil seal be missing on a valve?

Bypassing the lines is a quick and dirty way to rule out a few things. FWIW: The three studs holding the pump on can't take a lot of torque. They need to be tight, but don't wail on them when you put together again. All the best, 2Pbfeet

While "When you have a hammer, every problem looks like a nail....", I do think that the issue sounds like an air leak or a bad IP. While you are waiting, I would replace as much of the low pressure line as you can, and while you do that, look for any dirt, hair, scratches, cracks, anything that...

I highly doubt it. Nice thought. That is on the mechanical side of the pump. If 17 were leaking and the pump internals were bad, perhaps, but then you would probably be getting fuel in your oil. All the best, 2Pbfeet

Try pumping out of the main tank with the aux pump.

Sounds like fun. The VFD pump controller will make life easier for your generator. As a general rule, I would suggest line reactors on the 3 phase side (if it is 3 phase), and some extra toroids or an EMI snubber on the input side. (E.g. something like this one 20A@240V)...

Offshore oil rigs? What are your anticipated loads at home? Peak kW? kWh/day? Are you thinking this is post hurricane, or off-grid? I think that the existing '803A waveforms are about as good as it gets in my opinion. One thing I would point out that I am sure that you know is that diesel...

Are you sure that the float moves freely and isn't binding in the tank? If there is residue (gunk) on the sender it may not work well. A little carb cleaner goes a long way. I think that it is always worth checking the gauge values while moving the float outside of the tank and making sure that...