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Sure, just do it "to code". Edit: Jim C., I know you know, but L0 is neutral unless it's bonded to ground, which mine isn't. I think he's asking if it would be OK to add another lug for earth ground that's not bonded to neutral. L2 isn't used in single phase mode.

Dave, it does sound like the regulator is not doing its job. It supplies current to CVT1 when the generator output voltage needs to be reduced. If it can't supply enough current, the voltage will go up. The more load is put on the generator, the more current the regulator needs to supply. I...

1oldiron already load tested the generator to 12 kW without incident. Now if he runs it for a few tens of hours he can find out if there are any problems with the system like carbon buildup, etc.. Let's take this as an opportunity to learn some things about 003A exhaust systems. :beer:

Sewerzuk has made a thread here, and some YouTube videos, about how to convert the 15kW MEP-004A and larger to single phase while still being able to get rated power. I do agree with the posts above though, that you would probably have plenty of power with an 003A. I sure do here. In a...

"Pot" is short for potentiometer, which is a variable resistor. If the pot is intended for a control panel, it usually has a shaft for a knob. If it's made to mount on a circuit board, it usually has a small protrusion like a screw head, with a slot for a screwdriver.

Could be dirty pot(s). Sealed ones are hard to do much with, other than exercising or replacing them. If you can get some good contact cleaner in them, that'll help. DeoxIT D5 is one.

I'd certainly want a neutral and a hot for 120V power. 120V equipment is designed to see that. Many/most 2-prong plugs are polarized for that reason.

There are some small differences between the 72-5020 board and the 72-5338 board, but it's things like resistor power ratings which don't really change anything operationally. Those numbers are silk screened onto the boards.

Ike, the parts manual that I have for the 002A lists 72-5020 and 72-5338 as the two AC regulators that were used. Both are configurable with jumpers for 60 Hz and 400 Hz. These are the same as the ones used in the 003A. Were there others?

No, the length of the cord won't change the frequency of the AC. Was the meter still whacky when you got to 60 Hz?

No doubt that if you want an exact replacement you need to check the dimensions. But if you're a little handy, you can drill new holes in the board and solder in a pot of different dimensions. That's what I did to repair one original regulator I worked on. If you do it right, the now holes...

The meter will swing pretty wildly if you're not near 60 Hz. My guess is that the engine is running too slow, but it's possible it's really running too fast as the meter indicates. You can get an inexpensive "Kill-a-Watt" meter and plug it in to the generator output to check frequency. If you...

Good clue here. Since the range of the front panel pot changes during the problem, it would seem the pot itself is not causing it. The suggestion of cleaning the voltage adjust pot on the regulator board is a good one. Maybe just replace it. Have you tried tapping on various components of...

Now you have to tell the rest of use how to tune an 003A to use the fuel like an 002A.

It's a great feeling to restore power with a generator during an outage. I wrote a step by step instruction sheet for our 003A, and my wife an kids have each practiced starting the generator and transferring power to the house, and then reversing the process to go back to commercial power. I...

Rubber is usually ground, not cut with a lathe tool. You'll probably do better with a Dremel tool and grindstone either hand held or mounted to the tool post.

You're absolutely right at T2 being another possibility when the generator output is too high, I should have mentioned that. I'm glad you knew to check it. The regulator senses generator output voltage after being transformed down by T2, so if that transformer fails, the regulator thinks the...

Make that Q3. There is no Q4 on the AC regulator board. This generator, and the 003A, use a special transformer, CVT1, to control the exciter field current. When the output voltage is too high, the regulator supplies current to the control windings of CVT1, causing it to reduce exciter...

You said "overcharging", which implies it's overcharging the 24v battery, but then you said you tried to turn it down with the knob, which makes it look like you mean the AC output is too high. What voltage are you getting? Is the control box that you swapped the one with the meters on it?

Wait a minute... 27 volts AC? Was that a typo and you measured 27 volts DC at the battery?