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If the installed starter has trouble cranking the engine, might it be a 24V unit?

It sounds like you have no problem at all. It is perfectly normal for a fairly large load like a big shop vac to drop the output voltage from 120.2 to 118.5. This is backed up by the fact that the shop light didn't cause the voltage to drop noticeably more. If you were working in direct...

I'm wondering if you have a bad connection at or near terminal 6 of the reconnect switch. That becomes the neutral, L0, and if that were floating around, you'd always have 240 from L1 to L3, but trying to draw a 120 load would shove L0 (neutral) off center and you'd get less than 120 on that...

Looking at the schematic, if the front panel meter shows a steady 240V, you have that at the L1 and L3 terminals of the reconnect switch. What do you read by measuring the voltage at the main output lugs when you have a load between L0 and L1, and between L0 and L3? Those two voltages should...

You said when you connect a load, the voltage does not drop. Are you measuring this at the output lugs or looking at the panel meter? If it does not drop at the lugs, but your lights in the house are dim, something is wrong after the generator.

In that case, I'd look for a dirty/corroded/loose connection in the output wiring, or something wrong in the reconnect switch. If the meter is showing 240V even with dimly lit bulbs connected, you must have a high resistance along the way. With no load, do you have 120 from L0 to L1 and L0 to...

David, if R4 also looks like it got hot, I'd say Q1 might have failed. Q2 could also be the problem, because if it fails, it could cause Q1 to fully conduct. If it's just R11, I'd suspect the 18V Zener diode, CR6. Any more detective work would require some voltage measurements while in...

Does the volt meter drop when you connect a load?

There is an overtemperature switch and I believe it's in the cylinder head. It will stop the engine if the temperature is too high.

Ha, I just noticed the typo in the quote from the manual I posted above. 60°C is 140°F, not 14°F. I assume they mean the temperature of the air coming out of the shutters.

From TM5-6115-585-12, page 3-10: When loaded to about 1/2 capacity, my 003A's shutters open fairly far in the summer, but usually not all the way. It takes long enough for them to start to open that I got a little nervous the first time I watched them.

Ike speaks the truth. I've run many different computers on old square wave inverters with no problems at all. I used to run my main work computer on a square wave inverter full time, powered by a car battery that was kept charged with a 13.8V power supply. Being so isolated from 120V power...

Those lawn tractor batteries can be amazing if you get a decent one. I've had the original one that came in my mower for 7 years now, and it cranked the engine for a good 30 seconds on the first startup this year without a problem. On the other hand, a crummy one is lucky to make it two seasons.

Not a problem, Jon. The circuits must be pretty similar, except for things like the 24V versus 120V fans.

ETN550, thanks for your post. Jonster emailed me a schematic that I thought was correct for his generator, but I just checked, and it's for an MEP-016B, so I've been helping him based on the wrong diagram!

If you have 24V on both sides of CR4 and not at the fan, then the wiring must have a problem. From the schematic, if the battery is installed and charged, the fan should run until the battery runs down, even if the charging system isn't working.

I suppose you could, or you could measure the voltage at the motor terminals to see if 24V is getting there.

I think you're seeing relay contacts that resemble the symbol for a capacitor. When A2S1, the master switch, is in the run position, and A3K4, a pair of contacts of the low fuel shutdown relay, is closed, the "noise kit fan", if you have one, should run. "A3K4", for example, is a set of...

Yes, Aircraft Spruce is a great supplier. They have a fuel-resistant grease called EZ-Turn that's made for lubricating fuel valves. It also works great on things like carb bowl gaskets as a non-hardening sealer.

Good point, Ike. The % rated current meter might just be vibrating to 20% when there's actually no load at all.