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The best thing to do is to start your own thread. If you go to the top of the screen on the forum there is a link for "Technical Manuals". You can go to the generator section and find the technical manual for your machine. There will be wiring diagrams in there. You can see a cleaned up...

I would troubleshoot all the switches first. That is where the wear or corrosion is going to take its toll first.

3 phase is the standard in industrial/commercial installations. You have to pay a premium to get 3 phase in a residential install. I see it occasionally. For most that have a shop at their home they are stuck with single phase unless they want to pay a lot more for 3 phase service.

I expect we are talking single phase which is a bigger challenge. On the plus side they may be able to change the starting capacitor and/or put in a different unloader to reduce the starting power required. Those things are maybes though and would require some experimentation. At best I expect...

+1 on everything Guyfang said. Until it will pull a steady 120% resistive load it isn't working correctly. High inrush loads like motor starts require a generator to be in top operating condition.

The way to test for wet stacking is to add load a little at a time. Starting an AC unit is way too much load at once. You need to find that point where it struggles and hold it there till it clears then bump it up a little. 500w increments using space heaters is a good way to go. A load bank...

If you want to maintain a minimum load on the generator for testing or whatever you just need an adjustable current switch and a power relay for the load switching...

If you want to have some fun and experiment with building something to measure power factor take a look at this - http://www.syscompdesign.com/assets/Images/AppNotes/power-factor-measurement.pdf There is a decent explanation there about what is going on.

Making a sensing circuit isn't so straight forward. You have to measure the current waveform and the voltage waveform then perform some math to get to apparent power. Your application doesn't require that level of sophistication. Just know that the load meter is assuming a 0.8 power factor. If...

The gauge lies. Divide it by 0.8 if you are running a resistive load. You'll be fine.