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I've seen something similar on other older diesels that I thought was just thermal cycling coupled with thermal stresss that lead to metal fatigue and cracks. I've seen it in both tubes, and castings. I would comment that it does not take that long running a diesel in an over fueled condition...

(y)(y) This is such great advice. I can't count the times I have seen similar things happen. A little forethought and planning can save a bunch of time and hassle. Around here, I track the gas stations that I know have their own back up power. All the best, 2Pbfeet

Thanks for the deep due diligence on your and Peter's (@peapvp) part! It is nice to know that on the 804/805 sets that there is no loss in capacity. All the best, 2PbFeet

Are the threads by WA Ross? E.g. https://www.eng-tips.com/viewthread.cfm?qid=168708 https://www.smokstak.com/forum/threads/bar-diamond-or-collins-connection-for-10-lead-1-phase-120-240.164502/ He seems very confident of his views, and they seem supported by diagrams that don't look crazy to me...

I think that you can't, really. @Guyfang wrote that the best way is to pull the tank (I didn't do that.) Second best, and it is definitely not as good as pulling the tank, is to run a borescope around and behind, but you can't see under the tank, or at least I couldn't. The process is a bit of...

@FarmingSmallKubota there are ultrasonic bolt removal services, but they aren't cheap around here. Speaking as a welder, I would not be TIG or arc welding that close to generator windings. I've always been told not to do it due to the induced currents and voltages, so I have never done it. On a...

What about the electronics in the machine, e.g. the voltage regulator? All the best, Peter

Me, too. The hole to hole variance is too subtle to be easily identified by my eyes. I have a truck where the factory (!) used something like an angle grinder to set alignment marks in the floats and tanks. All the best, 2Pbfeet

It would have been pretty straightforward to test the balance with a second bearing support for the engine side. I don't see any balance drill holes in the fan assembly, which argues to me that there wasn't a factory process, but doesn't say anything to me about potential imbalance. The wiring...

That's great. I would just check that the missing screws aren't behind or under the fuel tank. It would not be pleasant if a loose screw wore a hole in the tank. (That tip is courtesy of @Guyfang, who put the fear of that into me.) With only two screws in, I would double check that the...

And the prize for attention to detail goes to... Wow! Nice job. All the best, 2Pbfeet

Well, with three, you have lots of room to compare and contrast. Sounds like a fun project. (y)(y) I think starting with the pop test on the injectors is a great place to start. After truly imbalanced crank/piston/rods, I think imbalanced injection is the one most likely to add excessive...

I have chased NVM on more than an few items, and speaking as a non-professional, it always feels to me like a swamp. Folks who make zillions of something can put it into a computer model and simulate it or test it and find the combination of tweaks and absorbers to make a difference. For the...

I agree. In the third photo above from @Scoobyshep there is a wire that appears to have burn damage in several places, though of course, it could be a stain from something else. That might be a circuit to start the search at. All the best, 2PbFeet

+1 on heat. It is your friend here, but a gear puller is probably the tool that you want. Did you get the pump timed to the engine already? It really helps reinstallation. Here's a video of a similar Stanadyne removal from a JD engine; PM if you need a rebuilder. I know a good one in SC. All...

True. There is always sending the coastal radiators out for anodizing. Having maintained equipment at a beach, I don't think radiator corrosion is a huge issue. Yes salt water gets to aluminum, but not quickly, and a little protection goes a long way. E.g. blocking direct wind from the ocean...

Thanks for sharing! Gotta love zip tying a spare fuse to the same fuel line the fuse holder is zip tied to. I do like the idiot light for power at the fuel pump. All the best, 2Pbfeet

@Light in the Dark thanks for stepping up on this one! +1 on a drop in. For me, plastic screw on filler neck funnels work well enough for adding coolant. I would rather not have new opening in the top to reduce the potential for leaks into the enclosure. I don't see much value in changing...

If it gets right down to it, Keyser makes custom racing radiators, many of them in a 16" double pass, but not a drop in as their standard is 2.375" thick. Custom quote form here; https://fast-d7f5.kxcdn.com/wp-content/uploads/2024/04/RadiatorForm2024.pdf All the best, 2Pbfeet

Noted thank you! The machine is in really good shape for its age. Ignoring the faded control panel and slightly weathered paint, it looks as good as my late-model units. I'm not sure why the rings are stuck, but the engine shows all signs of being healthy. Oil pressure is 60 psi cold/50 psi...