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I think more detail about what you've done to test everything would be helpful at this point.

Sounds like you need to start at the beginning and do some testing. Start with the MPU and speed controller. If that isn't working you'll not flash the field to make power.

I assume you've tried holding the switch in the START position after the engine starts? Do you get any voltage while you are in START?

Can you post a recap of what you've done so far? Do you have the TMs and have you reviewed the troublshooting in the TM?

You have to dig around and find them. Those engines are used in more than the MEP generators. Search for Lister LPW4 parts. I gave you a couple of examples of searching for parts on ebay in response to your PM.

Adding another phase in the mix isn't a big deal. You can look at your panel and see if you have any loads that it makes sense to split off into another panel for your third phase. For the house I'm going to build soon it will have AC and DC power distribution. Anything that can run directly...

Totally get that. My wife gave me SOOOO much grief for all the time and effort I was putting into the MEPs THEN we had a serious power outage and all was forgiven. Now she doesn't blink when I'm doing these projects.

You may can reach out to a company such as this to see if they make a generator head that will fit the engine. https://centralgagenerator.com/product/164d-16-5-kw-single-bearing/ I can't image this is going to be easy or less expensive than selling/trading the MEP804 for a more suitable machine.

The way to think about it is like this, Using 2 legs means you paid for a 15kw generator but GOT a 10kw usable generator. Anything you put on that third leg gets you closer to what you paid for from a load capacity standpoint. I think your chances of converting it to single phase is 70/30 in...

These things have a generous engineering overhead. You can run them unbalanced no problem. You won't be able to get full nameplate out of it but if you keep your demand down around 8-9kw then its not really a problem. Its not ideal but people worry about it far more than they need to (assuming...

Roger that. 0.27 gph sounds closer to what I would expect. Maybe a little higher but not so bad.

I've not torn down a 804 but if its like the smaller units that I have torn down its easiest to pull the engine and alternator together then separate them.

Do the inverters operate in parallel and do they have transfer switches for generator power pass-through? If the answers to those questions are YES then you can't even use two phases of the generator. If the inverters have pass-through capability then they each will have to power separate 120v...

+1, There are solutions for that problem but they will require some specialized help to implement correctly.

With zero concern given for how most residential panels are installed regarding load balance, a 5a difference is quite good and is of no consequence to the generator. From the fuel burn perspective you must have had some load on it to burn 0.4 gph. The fuel burn at MAX load on one of those...

Agree that head temp is the better place to monitor. You can find thermocouples that are shaped to go under bolt heads. Very common in aviation. You'll need a bit more circuitry to read a thermocouple but your autostart will work better. The 003s start well when they are adequately preheated...

I think some of those quotes may be mine but that said I’ve not been able to get my hands on one to experiment on. Based on the lack of solid data you may be better served by selling it and buying a generator known to provide single phase. If you decide to go into the stator to attempt a mod...

Preheat is active in the START position as well as the PREHEAT position.

Without a way to sync them it’s going to end badly. I don’t recommend trying it.

Has it been rodent proofed? That sounds like a classic rodent attack. :(