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the diode issue is very easy to diagnos

right, with the wires disconnected, it cannot know if it has a short or to heavy a load. if it says it does it is the box, if the indicator goes away then maybe it does have a problem with the gen. i don't see how an internal gen head problem would show up since it has to have to much current...

disconnect the wires from the 4 rear right terminals and see that the problem goes away or if it still 'says' there is a problem. also take the box apart and look for water damage as george said. are you sure the cables from the contactor to the output connection have not rubbed thru on the back...

only with the gen running and then there would be an obvious heavy load on the gen. this is a safety for unattended running. in this case it has not been started when it shows short. something in the malfunction indicator has probably gone bad or gotten wet.

keep in mind there are 2 completely different systems here, 1 is the DC system that starts and runs the engine, the other is the AC system that monitors and controls that part of the system. it seems common for the wires from the main AC contactor to the output lugs to wear thru on the back of...

yes, i think you have at least 2 problems, but sometimes they are related to each other. just start with 1 and solve it. R10 is just 1 of 3, one for each phase, that are to load the sensing transformers so the circuit can see how much current is being generated. the more current the gen puts...

CR1 is just there to prevent you from installing batteries backwards, otherwise you don't need it. but, you have other problems. power from battery goes to CR1, thru it to the throw of the dead crank switch, then when normal pos to the emerg stop switch, thru that to CB1 and then on to power the...

these provide load for the current sensing transformer so the load circuit knows the load.

well, if you spray electrics with water you may get problems. pull the top cover gen end and blow everything dry. the dust that comes in many of these is a good insulator when dry, but when wet who knows. i literally pull both top covers and pressure wash everything and then blow dry and have...