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There is no fuel cutoff solenoid for the AUX fill on the 8xx machines. If you gravity feed your AUX source it will overflow the tank in the generator.

Great Ted, Let us know how it turns out.

The way to test for wet stacking is to add load a little at a time. Starting an AC unit is way too much load at once. You need to find that point where it struggles and hold it there till it clears then bump it up a little. 500w increments using space heaters is a good way to go. A load bank...

Can you pick up a for parts Yanmar L70 off ebay and get it going?

They flushed the cooling system with oil? Does it say what kind of oil?

Yes, you are right. L1 and L3 are the correct ones.

Check the voltage between L2 and L3 with the generator running. You should get 240v.

Can you explain more about how you have them hooked up? Maybe a few photos of the connections? You need to set it to 240v.

That sounds like you have the generator set for 120v only output. What is the output switch behind the instrument panel set to (120v or 208v or 240v?) Only change the switch position with the generator off.

And if you want to redneck it up a bit you can use your bathroom scale to weigh the tongue. Build a balance beam to split the weight keep the amount of force on the scale reasonable. https://www.etrailer.com/faq-how-to-determine-trailer-tongue-weight.aspx

You should set the generator so you get about 10% of the total weight on the tongue. That will make sure it is stable when towing.

Yep. That would do it.

The why is because three of the windings are premenantly joined in a {edit} Y configuration inside the head. That locks you into delta only operation. What I've wanted to see is how possible it would be to trace wire 10 back into the generator head and find the connection point where the three...

The 804 has a 10 wire head. It is not possible to connect it zig-zag for single phase. You will burn it out trying.

See if this would work for you. http://www.steelsoldiers.com/showthread.php?134803-MEP-831a-Troubleshooting&p=1667559&viewfull=1#post1667559

I hope to be able to pick one up on the east coast when I'm done with the west coast project. It would be much more convenient than the water heater element setup.

You can find a few MEP-831 machines on flea-bay.

Thats a good question. I've been using the Rotella 5w40 in my air cooled engines including the 831 and they pull full load with no problem. Diesel over JP8 should not be the source of the problem. Let us know what you find out.

After you are sure you've purged the fuel system I would recommend looking at the air intake path. Black smoke is a sign of too much fuel in relation to the amount of air. An air restriction will put you down on power and make it blow black smoke. Lots of black smoke. Take a look at the intake...

Excellent! Glad it was simple. The contacts on the E-stop could be a little dirty. They are self cleaning. Just cycle the button a few times.