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Are both batteries the same age and size? Have you searched around for 24V when your set's dead crank is set to OFF? I am not familiar with this larger set, but can you use zip ties to lock the fuel stop solenoid 'open' no matter the battery issue, to just keep the set online?

Any issue with holding load during the warm months?

Just send me a direct message and we can discuss the gauge. But you can view the listing here: https://www.steelsoldiers.com/threads/mep-fuel-gauge-fits-5-200kw-gensets-88-21103-beede-945331-6625-01-366-0193-70-ea.199406/ Thanks

You can check the sender, but in my experience when its pegged far right its a dead gauge. If you are looking for a replacement, I have them listed in the classified section.

It means it has undergone a rebuild process. Rebuilt engine, refurbishment of genhead and accessories, etc. The hourmeter should have been changed when the engine was (so its not reflective of the actual machine usage... just its newest lease on life).

OK let me back up... it is possible that you are sucking air if this only happens under PRIME AUX, as its a pulling line, versus a pushing line. Did you fab up the fuel hose from the external tank to your machine, or was it factory made? Have you checked any of the fittings behind the fuel tank...

These machines are self priming. The amount of air in the system would pass rather quickly under prime, and definitely not be sustained. Is your return line dumping back to the stock tank in the machine, or to this larger external tank?

Are you certain you hear bubbling? You should be hearing a dribble of the fuel being returned to the tank. The set never runs on an auxiliary fuel tank... it simply refills itself via double float switch. I would suggest brushing up on the TM for the unit to get a better understanding of the...

Nice little bit of security right there.

Make your life easier and pull the muffler and air cleaner. Trust me. And as the others have said, dremel will take them off the quickest. Just be careful not to lose track and cut up the barb on the hard line.

I didn't know. Thanks for the info Kurt.

That fuse holder is empty (and not wired properly... the wire appears to be directly where the fuse would be held). I would check to make sure the wires are positioned correctly, and pop in an appropriate fuse. I don't know if the fuse requirements are different on the 15kw units compared to the...

Just take your time, and put a touch of oil on the ends of each return line section and they will slide onto the barbs easily. Should be the last time you have to do the job.

Yeah all of the soft lines you have photographed need to go. You can go with the OEM Contitech stuff, or go with Gates 27000 1/8" fuel line (available on the spool at a lot of local auto stores). Use hose clamps wherever possible on the primary lines, and little zip ties up on the returns...

What model genset do you have?

That would be me... and they can be found in my signature.

That manual can be found in the correct thread in the TM forum that was called out: https://steelsoldiers.com/threads/all-the-manuals-for-the-mep-802-5kw-generator-and-mep-803-10kw-generator.148871/ Direct link to the manual from that posting is here...

Well if the engine runs, thats half the battle. The genhead can be repaired if something has gone wrong (or completely removed and replaced). I might have an extra 10K genhead that could ship on a pallet, if the need arose (and new in box units are available, some even on the big auction site)...

Do the pumps look original to the set, or do they appear to have been swapped out? Have you checked your fuel tank for floating trash, or the strainers/filters at the South end of the fuel pumps? How do your supply lines look... any seeping or strange appearance? They could be swelling.

Do your voltage figures change when you adjust the distance from the face to the flywheel?