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I don't know about your engine, but moving the throttle does not always mean that the pump volume regulator is moving. Have you thought of buying a manual? @Guyfang found a few on the bay site awhile back. Deutz engines are generally self priming. I haven't seen this model in a long time, but...

+1 on SeaFoam. If you are really concerned, pull the injector and let it sit in carburetor cleaner. Those engines were used all over and are pretty bullet proof in my experience, but I've never dealt with one that had sat for 18 years.

Or check with the pump guy: thepumpguysc@aol.com Search the web on that address, if you want to read up on him. Lots of folks have gotten injectors and pumps rebuilt by him. He's quite helpful. All the best, @2Pbfeet

If it comes down to rebuilding, I know someone who has been rebuilding injection pumps for 30 odd years. All the best, 2Pbfeet

I am of the same view. @heimlich I have a similar kW rated diesel generator without an enclosure, and I would happily trade you for one with an enclosure.;) That said, if you really think that you want to strip it down, I would suggest that selling your 802A , and buying an 1800 or 3600rpm...

@tarster There is always the possibility that your alternator just needs some new diodes. Not generally all that pricey.

While I suspect something is off on your governor or rack, or possibly timing, I do wonder if it would be worth your while to clean your fuel lines downstream of the final filter. Cylinder 1 not firing either means the injector just plugged, or the pump isn't coming up to pressure. Since the...

One on EBay for about $200 https://www.ebay.com/itm/256437803664 There are other 24V 40A alternators available, but might take some drilling/rewiring. YMMV...

Making progress! I agree with @Light in the Dark that I think it is time to pull your injectors and check for function and spray patterns. Two of your cylinders appear not to be igniting. That will cause an under speed that the governor will react to by providing more fuel (too much fuel, in...

I agree. You are preaching to the choir on that, and sorry for your problems. What is that a photo of? Don't get me started on hydraulic fitting sizing. I keep a fifteen or sixteen page printout in the shop to help me. All the best, 2Pbfeet

That is certainly true that the engines aren't straight SAE, but the dash 202s seem to fit the final filter bolt on mine. Like @777Jackpot's experience, the o-rings that were supplied with the filters that I purchased did not include o-rings for the bolt. None of my metric o-rings seemed to...

I believe that the little o-rings are dash 202, viton. E.g. https://www.mcmaster.com/catalog/130/4002/9464K118 All the best, 2Pbfeet

It's a cheap part, but fiddly, unless you buy the OEM, which is not that cheap. If it was me, I would first try tightening it, and then if that doesn't work, clean the outside, open the joint up and cleaning the surfaces with carb cleaner and trying again before buying another. I have a drawer...

@peapvp Thanks! That was a detailed explanation. I think that I now understand your earlier post. I appreciate you taking the time to explain it. All the best, 2Pbfeet

If you do remove the pump, I would make sure that on re-installation you get the pin on the pump back into the "U" shaped yoke to engage the governor. Lots of videos on how to do it available. You can see the yoke by loosening the nut below the pump and removing the small trapezoidal plate...

@peapvp Just curious: when you say that the "DC Field Volt / Current response" doesn't match, I think of several possibilities, not all of them bad, or good. Can you elaborate a little? Are they deficient in some way? Is it correctable? e.g. does the DC field signal have more, say for example...

That's a messy, messy job.

I agree. I wired up a spider box to be able parallel the house, and be able to run additional heater loads from the spider, as well as the house loads (generator to spider, spider with two high amp outlets, one to the house, one to a 1.5-10kW heater). Kills two birds with one stone, so to speak...

That sounds like you have engineered a really nice system, congratulations. I especially like your charging setup. Are you on wood heat? Is your hot water a heat pump? Just curious. Do you have a ballpark of the total cost? Over the years, I have seen a few Homestead Engineering videos, and...

@heimlich Just FYI, purely resistive loads, such as stoves, and heaters, make better load banks than motor based loads, as the motors can impose some complexities on the power and power quality. (Reactive power, and harmonics)...