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I had thought about using a loom to wrap them. The issue you can cause there is with heat dissipation. I'll need to check the wire size and make sure wrapping it up won't cause any heat problems.

As part of checking the damage on the MEP803 I picked up today I noticed something that should be resolved in the generator electrical section. The way the wires are routed from the reconnect switch to the terminals below they cross over some sharp metal edges with no protection. I can see on...

That is one great setup.

I picked it up today. The generator has a bit of a bash on its top from something hitting it pretty hard. I took it apart to make sure there wasn't any hidden damage. There wasn't. Cosmetic only. The particular generator came with fluids still in it and a set of batteries. The power cables...

You sure its not 1.21 jiga-watts? ;)

That looks about right. You will read lower than normal on a pure resistive load. The meter is calibrated for a power factor of 0.8. That is the reason for the difference. If you take 9960w * 0.8 you should read just under 80%. I wouldn't quibble over 5% error so if its reading about 75% I...

Anytime. You can use something like this to make your load bank using a metal or plastic 55 gal drum. http://www.amazon.com/dp/B005Q6777C/?tag=waterheaterti-20

I use a plastic bucket and mount the elements facing down into the bucket through the top. I cut a hole in the top for a garden hose and cut a small hole in the side of the bucket at the level of the lid. Water goes in the top and runs out the overflow hole on the side. The water won't get hot...

Water heater elements are a lot cheaper for the wattage.

Rig up several of these for a good load - http://www.homedepot.com/p/Unbranded-1-500-Watt-Utility-Milkhouse-Thermostat-Portable-Fan-Heater-DQ1409/205202877

That would certainly cause it. Glad to hear you have it working right. Have fun.

OK. That doesn't always happen. See if you can take the voltage reading at the convenience outlet across the range of the voltage knob. Also check and see what the setting of the voltage output switch is behind the control panel.

What do you have the voltage selector behind the instrument panel set to? What is the voltage on the convenience outlet when you adjust the voltage knob? When you turn the voltage knob all the way to the right do you get an overvolt alarm on the alarm panel?

A hair dryer isn't going to be enough load. Unless you run it on low it will probably trip the GFCI again. I use water heater elements in a bucket of water to load test the machines I work on. Dead simple and it works. There is risk there you need to mitigate. Make sure no one can touch live...

I would siphon or drain the fuel out and see if the gauge changes. Or run it and see if the fuel level drops. That is the more fun thing to do. ;) For the reset you need to open the gauge panel and look to the left. You will see the overload reset on the GFCI there towards the bottom. Push it...

The gauges are balanced coil mechanisms. They don't go to zero when power is removed. They can bounce around and will stop where ever they want.

Even if you can you should come back and tell us about it. ;)

Is the E-Stop pulled out?

If you search around you should be able to find the specs on that ATS. I'm sure with a little work you could build a controller that will switch it for you if you like. I've looked at buying one of the Generac ATS to play with since you can get them second hand pretty cheap.

This is what a carboned up unit looks like when you first try to load it - https://www.youtube.com/watch?v=j9cI1l77fbg The generator in the video after cleaning up and blowing out runs great and will pull a full load again. These generators are a little different. If you haven't done so you...