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Welcome to the '803 club. Yes there are a zillion #10 nuts in awkward places, and I think as it is not desirable to have them vibrating around, I think it is important to find them all. Magnetic pickup wands and a vacuum with a crevice nozzle helped me. Bonus: I found fasteners that I was not...

I agree with you that they usually are remanufactured engines, but the document that @kloppk posted lists remanufactured or new. All the best, 2Pbfeet

In addition to @Mullaney's comment above, and this is may sound horribly tedious, but I think all of the wires and wiring ought to be checked. The fully pegged fuel gauge is suggestive to me of a bit erroneous wiring, including checking on the solenoid wiring and function. All the best, 2Pbfeet

Can you elaborate on the "rubber band" question a bit? The original hose is rubber with a woven outer cover, so stiff compared to say clear vinyl tubing that is not usually diesel compatible. Generally, if the outside woven cover is wet or weeping, the hose is cracking, but the woven cover can...

Is that braided hose actually attached? In one photo the hose looks almost broken. If you can tightly fasten the hose on, great. If not, I suspect you need a new return hose. They do age, crack, and weep.. I like the spring clips as the pressure on the hose is uniform around the circumference of...

That's some collection of custom vehicles that you got to experience! Wow! All the best, 2Pbfeet

That looks like a new engine was put in. Lucky you! All the best, 2Pbfeet

@Scoobyshep funny! And not the first time that I have heard a story with regards to improving the effectiveness of the ground rod. The manual above suggests a salt solution poured around the rod, though I have read elsewhere that Epsom salts (MgSO4) are more effective and more persistant. EDIT...

👍👍 Personally, I prefer to learn from someone else's errors if I can, but that doesn't stop me from making lots of my own.😆

+1 on corded. I have an inexpensive SDS adapter. It works a treat. I also have an adapter for a demolition hammer as well when a little more persuasion is needed, as the rocks here are soft, though the gravel can be quite hard in places locally. Though I would say standing up on a ladder with...

Is your unit a Tier 1 or a Tier 2 reset? The one under the oil filter is usually the National Security emissions exemption statement. Not having a remanufactured label suggests to me that whatever caused the unit to be sent for reset wasn't something significant to the engine, per the document...

Thanks, and posted in TM Uploads. All the best, 2Pbfeet

The manual is from Marathon for their smaller light towers. "These are small, capacitor regulated generators. The most common model numbers include 201CSA5411 which is a 6kW unit and the 201CSA5420 which is an 8 kW unit." Table on page 6 lists parts for and covered units, generally 6-10kW. Also...

I'd be happy to, but I didn't think that I had the privilege to do so. Where would be the best location as I don't know of a Marathon light tower military version. (My ignorance, I am sure.) All the best, 2Pbfeet

I think that lack of oil might behind Generac's call for once daily checks on oil levels on their air cooled units. All the best, 2Pbfeet

@HamAndEggs FWIW: there are troubleshooting steps from Marathon below, along with the power generation circuits (brushless) at the end of this Marathon manual. https://www.marathongenerators.com/generators/docs/manuals/SP0021.pdf I think that the general issue with capacitor regulated...

When a unit goes for a Tier 1 or Tier 2 reset, there is supposed to be a data plate that includes the hours of the hour meter when the reset was done. The document that @kloppk linked above contains the conditions under which an hour meter must be replaced during a reset. Actually, all in all...

I've bought from Friday Parts, but only occasionally for parts that I didn't find elsewhere. They seemed reasonable to me. My bet is also that the tappet rod is the only damage, but it would be good to know whether the root cause was carbon caked valves or a defective lifter, or... I think...

FWIW: I wrapped the intermediate battery cable with nylon hydraulic hose protector. I think it is much more abrasion resistant than electrical insulation. I also use it for wire loom in places where the wires might rub, or where I anticipate needing to take the wiring apart for some reason. I...

Looks nice! Do you have fine screening on your three air intakes to exclude insects and rodents? All the best, 2Pbfeet