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I would figure out where your true center should be on this machine for the muffler placement, open the hole up in this plate, and install a large high temp grommet. Even if its not OEM, if you open the hole up, respective to center, the grommet will grab the thickness of the plate, and take up...

You probably got 4 different measurements, because this plugs tolerance was not that great. Thats probably why they have the copper sealing washer... takes up the difference in manufacturing tolerances (and probably thermal cycling changes too). How varied were your 4 measurements?

The relays can often wiggle loose too, even with the hold down clips in place. I sold an 803 to a gent in TX and it would not start upon arrival... after some troubleshooting, it was determined that one or more relays had jigged about a bit in the ride down. All were reset and clips put back...

This is why I cover the large cutout under the engine with 1/4" hardware cloth and sheet metal screws on every machine I go through. The holes under the batteries are covered properly with the batteries and trays in place, but the rodents go into the engine bay through the large cutout, and...

Nesting there is very common... did you find chewed wires or any wire issues? Did you undo the connections, clean, and reassemble? Past removing the nest... what else did you do? Where this nest is, would not necessarily change the issue you were having (as this is before the contactor down to...

Which also means the chassis is hot when the bar is in place... lucky you didn't get 'bit'. Thanks Kurt!

See this is why I deferred. This makes absolute sense, and had I been thinking about it more... the set produces power the moment its on, so it absolutely has to be from somewhere on the outbound circuit giving you hell. Thanks Guy.

As this is a brushless head, and the rotor is supported by a central bushing... there are no parts which contact. It sounds like you have an issue with either the rotor or the stator (my gut feeling is you have a winding problem in the stator). I would not turn this machine on again until more...

Can you tell us what/how it was resolved?

I've had real good luck with this (and I tried it on a recommendation found here in SS): https://www.amazon.com/Hosa-D5S-6-DeoxIT-Contact-Cleaner/dp/B00006LVEU Been using it for the last 3+ years with no complaints at all.

If you are getting a short circuit light, this knowledge will not change anything. I think you need to get a GOOD contact spray cleaner and when the machine is off, take the roof off and deoxidize the phase selection switch and ALL switches and contacts in the machine. Corrosion in the switches...

Thank you for clarifying. This switch only tells the gauges what to show. Your phase selection switch is on the wall behind these gauges (where the voltage regulator is mounted). The phase switch should only be moved when the machine is OFF... no exceptions.

Can you tell me what 'switch' it is you keep referencing?

Came into my inbox, sharing with anyone that can use it. Your mileage may vary. Their site does carry Onan items too. https://shop.cummins.com/CSSNAStore/s/?store=US

When the battle short is turned on, you will not be able to crank the set until it is reset. Have you referenced the -24 manual for 'ENGINE CRANKS BUT FAILS TO START' steps? The first step is to verify the battery charge... if your solenoid is not holding OPEN during crank, either your batteries...

The Lister in the 802 is not the world's most advanced (and efficient) engine... definitely an old school engine compared to the Kubota in the 1030. That does have some benefits though, outside of fuel burn.

Yeah find the data plate and custom engrave the trailing 6 to a zero and move on with life. Make all the paperwork dorks happy.

Here is a plotted chart for a variation of the D902 I could find online... it doesn't necessarily discuss under loads, but it does plot at various RPM It came from here: https://global.engine.kubota.co.jp/en/technology/tvcr/img/sheetcatalog_d902-k_20220401_A4ill.pdf

The 1030 fuel consumption at rated load is .34GPH: https://www.marcorsyscom.marines.mil/Portals/105/PfM/LCES/ES/Power%20Team/Mobile%20Power/Info%20Sheets/GENERATORSET5KW60HZAMMPSSKIDMOUNTED.pdf?ver=2018-11-13-150411-423

I just looked up what this Kubota model goes for now... almost 8k (closer to 10k list price). These (historically) 'very expensive' MEPs look like bargains right now.