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Thanks for the kind words Craig, Check out this post and download the diagram I've been working to clean up. It may make tracing circuits easier. http://www.steelsoldiers.com/showthread.php?159693-MEP-Drawing-restoration&p=1933214&viewfull=1#post1933214

Time to break out the manual and see if you have power in all the right places.

Did you pull out the E-Stop switch and check that the circuit breaker behind the control panel was pushed in? Also, have you read any of the manuals about how to operate it?

I've not done a VR conversion but there are several posts here and on Smokestack forums if you do a quick search. I assume you are going the sx460 route?

Is this an actual MEP or is it the Onan flavor? That doesn't look like the MEP version.

Nice job!

Its true that in a perfect world there would be no imbalance. Anytime you allow single phase loads on a multi-phase source you WILL have phase load imbalances. What this does is causes uneven heating in coils and higher neutral currents. Normally this is a bad thing. If the generator was wound...

Agreed that it isn't the best scenario. But in the world of you run what you got.. Thats how it goes. The reality is that in a residential backup situation we aren't going to run these machines hard or long. Sure, and imbalance is bad. Its worse for a machine that runs at high loads for long...

If you connect it up that way it will be 208v. The power will be 120 degree out of phase instead of 180 degrees. That will be ok for most things but anything with a 240v motor will run hotter than normal. Any of the 120v loads will see normal power. I expect you already understand that you will...

http://www.governors-america.com/documents/PIB1007%20A%20SLC100%203%20kW%20Gen%20Set.pdf There is the setup for the governor. You can ask them about buying a new one.

If you are doing a single phase connection it will be a 4-wire setup. Using industry standard color codes your two load wires will be black and red. The blue will only be used for 3-phase 5-wire setups. White is neutral and green/bare is ground.

For sure switch them out as a test. You can buy new ones for a few hundred dollars. They have recently become available. You can adjust the magnet. That is not likely your problem. Get the surging under control first. Then tweak the magnet only if it doesn't shut down correctly.

Use the big ground lug and you will be in good shape. The terminals there on right are just for bonding the ground and neutral.

If it goes from stable to unstable with no other changes that is a classic symptom of a failing governor module.

Be sure to evaluate everything in the circuit upstream of the GFI. You could cause damage at 20a. The wires are pretty small.

One of the things I do is to take the return line at the tank off and put it in a container to see the fuel flow back through the system. It should be a nice steady trickle. You can easily see if you are getting a lot of air or if you have some other problem with fuel flow.

Are you getting fuel all the way back to the tank?

Ok. That means you likely have a blockage in the fuel return line at the end of the hard line. Its the rubber line that goes back through and into a fitting at the top of the tank. Its a 4mm line if I remember correctly.

Did you check both filters? You have a large one and a small one. The small one is next to the hard line and a real pain to remove. Sounds like the small one is plugged.

I think the lesson for all of us is to be prepared to walk away and demand a refund if what purchased isn't being delivered. For sure its a hard thing to do if you have invested a significant amount of time and effort to get there to pick up the stuff. If GL has to refund purchases voluntarily...