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@DieselDr, thanks. Not what I assumed when I read "rotary hammer". All the best, 2Pbfeet

@DieselDr Welcome to the forum. It is always great to have a diesel expert around! A 5HP rotary hammer can have some pretty impressive startup surges. Like an AC, they startup under a load, and the starting surge is not a trivial draw in my book. If you need to operate it on this generator, I...

Nice diagnosis and explanation! Very clear and to the point, in my opinion. Thanks for the write up. All the best, 2Pbfeet

I would bear in mind that ChatGPT excels at approximate answers, not necessarily perfect ones. "Trust but verify..." All the best, 2Pbfeet

If you do put it on a cart, I would consider a few trailer jacks/blocks to be able to put the generator on a solid footing when it runs... vibration is not a friend. All the best, 2Pbfeet

I used 1/8 stainless mesh to help keep insects (mud dauber wasps, in particular) out, and used stainless safety wire to attach the screens. After installation, I painted the side vents in matching colors. I use 1/8" around here a lot to reduce the impact of flying embers in during wildfires...

White smoke can happen for a variety of reasons, and there is a nice summary of things to consider here https://www.capitalremanexchange.com/causes-of-diesel-engine-smoke-by-color/ (As a general rule, I think it is useful to be able to narrow the list of potential issues by understanding smoke...

You might want to consider it for the existing oil, or is that what you meant? All the best, 2Pbfeet

Thanks! From a couple hundred miles away, the oil looks ok.;) If the oil doesn't smell strongly of diesel, and if the oil level isn't high, it is probably something else. I hope that the pressure gauge will be helpful. All the best, 2Pbfeet

I suspect that the alternator mostly idles along. Post engine start up, there will be an in rush to recharge the batteries, higher in AGM batteries, but the total power draw isn't going to be much (as @kloppk showed above). It would be interesting to know if there is/was a use of the generators...

I'm curious about the 4A number on the regulator, as doesn't the TM call out the original Prestolite as either 8EM3005CA or 8RM3005CA (which I think is a typo for a 8MR3005CA), specified as 18A, with a 30A fuse, and wasn't that specification for the alternator specification later upgraded to a...

Worst case to me is whatever I find the most painful... there are more than a few minor ways to have low oil pressure. Such as someone grabbing a gallon of 10W30 instead of the 15W40 that they meant to grab...or the sensor being off. All the best, 2Pbfeet

Different size (group) batteries from the same label often have very different lifetimes, so I think it is hard to generalize, so I wouldn't assume that the quality would carry over from one size to another. There was a major supplier that was notorious for having very different capacities and...

Yes, I was wondering about the possibility of diesel in the oil. Low oil pressure, plus clean looking oil in a diesel engine always makes me wonder about possible fuel dilution. Water in oil tends neither to look clean nor be low viscosity (aka low pressure). With a lot of water in the oil, you...

Sounds like a plan. How does the oil smell? All the best, 2Pbfeet

I also would be interested what the mechanical gauge reads. What kind of oil do you have in your 803? How did the oil look when you got it? 1400 to 1500 hours would low hours for wear on an original engine, but as a reset, there are other possibilities if the oil pressure is that low. All the...

Do you know of a source for boots? Thanks, 2Pbfeet

I would do it!

Where is the load bank supposed to be in that diagram? That looks like 28V was used as part of the connector power control circuit to not apply power to the aircraft until the safety circuit closed, after voltage and phase order were correct. All the best, 2Pbfeet

Spiders are often available used as well. Just make sure it has the outlets that you want. e.g. https://www.ebay.com/itm/404892933551 GFCIs do go bad, but the usual reason is that either there is a line / neutral/ground wiring error, or that some load is being plugged in or unplugged while it...