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Read the other post, but the overload light can likely be solved with Deoxit. ( I just did this today and my 802a pulls 5000 watts without issue) The surging may be a result of an over aggressively tuned droop control. This is pretty easy to adjust.

I can attest that this works. I have an 802a that could not hold any load over 500 watts without throwing an overload after 1 minute. After Deoxit'ing it , it happily pulled 5000 watts without missing a beat.

There is a wide array of types of Mil spec wire. I've purchased this style from Aircraft Spruce before https://www.aircraftspruce.com/catalog/elpages/unshieldlwire.php The last digits are gauge and color

Every time I think about moving back to the midwest, I start thinking I need to build an underground bunker/house. Fires, tornados, ice storms, trees falling? No problem.

2x Good job being prepared!

That's a cool setup. Is there a Mxxxx designation for that setup? I thought I could do something similar by building a 7-8" tall fuel tank riser, but didn't have a burning need right now.

I picked up a Schutt LTT-HC trailer with an 803a on it. Looking at the bolt patterns and dimensions, it appears two 802 s will mount facing side-to-side, but I can't find any pictures of this config online. (Just MEP-1030s) Anyone have a photo of this setup?

Jack it up, take the tires off, no more preload.

That is really cool. It also answers a question whether the 802a/803a series can be paralleled with the right controls. Was the engine modified with an electronic governor or does it still have the OEM mechanical governor?

Nice! That is a huge reduction.

Not being snarky here, but if you have to ask, you'd be better off fixing the existing system or paying someone to retrofit it for you. A Mebay DC30D generic generator controller would get you nearly all the funtionality of the MEP-802a panel plus autostart if it was hard wired for a single...

Any of you reuse your engines for log splitters, irrigation pumps, snow blowers, etc.? We were splitting wood this fall and an older gentleman showed up with a Continental Y69 4cyl powered log splitter. That thing was so much quieter and nicer than the other 3600 rpm box store splitters. It...

Nice setup! With that much solar, I won't even need the grid. How many Kwh is your battery bank? LFP batteries?

That's pretty close, my understanding was the voltage rating of the diodes in the rectifier bridge was too low and quad winding can burn them out under certain conditions. The fuse protects the quad winding if the regulator fails, but Kurts MOV mod clamps voltage transients from the quad...

Totally normal.

I'm feeling that. Started with one 802a, then bought a second because 2-is-1. Then thought having a 10k would be better for the shop, then needed a second one of those. Then got the spares running and needed a third for parts for the first two. Now I'm buying trailers, aux tanks, extra load...

100% Getting dead units running has turned into garage-therapy for me.

Unfortunately that area is common for rodent damage.

The schematics can be downloaded in the TMs section here. Here is a screenshot of the relay in question, K18 Here are some pictures of a partially disassembled machine I have. This can be accessed by removing the control panel side top cover. The relay is circled in red.

Likely all made in the same Chinese factory. I tried to find one with good reviews, since performance is hit or miss. You definitely should take the tester apart and clean it first before hooking up a good injector.