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SAE o-ring boss plugs are always difficult to break loose.
What brand of wrench were you using? There is huge variability in hex key quality/performance.
Roosamaster became Stanadyne. Very common pumps. It's not cost effective to rebuild a seized pump with new parts. Generally the pumps all have similar internals with different housings between models. If you can't find an identical housing you may find compatible internals.
Put your volt meter on each battery while cranking. If the battery voltage drops below 10 volts, the battery is toast. How old are these batteries? Can you see any bulging of the sides? Feel with your hand. Any bulging at all is bad. Each battery can be tested individually.
I have not been able to determine a cause of failure for this one. There are no signs of shoe lift. I'll dig deeper for the pump that did fail due to shoe lift.
There is a spring that holds the shoes and shoe retainer against the swashplate. If there is sufficient pressure in the case of the pump or sufficient vacuum on the suction the pressure can overcome the spring which lets the shoes lift off the swashplate. When they come back down they contact at...
I don't know how the pump being larger would make it better. The C9 Cat engines with HEUI did have a recall because one of the bearings in the pump was failing. With regards to axial piston pumps restriction on the case drain or suction can cause shoe lift which destroys the pump. The second...
The John Deere engines are not intended to be checked while running. Engines that are will have a two sided dipstick with running and stopped levels. I do have a 4045 engine in my fleet that pushes oil out of the dipstick if you pull it while running. There is nothing wrong with that engine. Do...
Even without glow plugs the engine should smooth out within a few seconds if you're above 40°F. That engine is making some unhappy sounds but they don't sound like bearings but there is something seriously wrong with the engine. Is it blowing bubbles in the cooling system? Have you done an oil...
Look into Donaldson Power Core air filters. There is nothing close in terms of performance and capacity. They have housing available with turbine separators to drop out the bulk of the dust.
The aftermarket return lines are the incorrect hose material for the application. They don't tolerate the temperature and you'll get cracks in the ends of the tube. You need to use Viton tubing. If you use Viton tubing you don't actually need the clamps. The OEM lines were Viton...
The most important condition is that there is only one connection between ground and the neutral. It doesn't matter much where this connection occurs, in the panel or generator enclosure. If you're wiring to your house lift the bond in the generator. If your using as a portable only, leave the...