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Yea I know CRC isn't the best... but Walmart had it on hand., and I would usually start with a bottle of Coke first (old Navy Trick at sea)... but I was all out! lol The emery board I was looking at is actually a polishing board (maybe 1600 grit), not the rough grit a-typical boards. Thanks...

Thanks! When I pulled the switch, it was REALLY dusty... and sounded and felt "gritty" when turning the knob....so I first blew it out with compressed air. Several of the contacts and screw terminals had a greenish or dark film on them and ohm ck showed issues, which either the CRC or a quick...

UPDATE...... Ok, I took the switch apart last night.. diligent about marking the position (and taking photos) of every gear, plunger, housing orientation, etc as I went through the stack of the switch. **For those saying it's a crazy "complex" switch... nahh... it's actually VERY basic...

Well after an entire can of CRC contacts stray, and wd40, and compressed air, and cleaning all contacts with a brass cone dremel wheel.... this switch STILL doesn't work right. It works on 3-phase, but single phase it still doesn't show voltage on the voltmeter.... The gen makes power fine, and...

Yes, I can read a wire diagram... Once I got my readers out.. (WOW tiny writing!! lol) OK, From S6-15/13 to M1 I get 83-volts. When I test the convenience outlets or L1/L3 I get the proper 120/240 volts, and the voltage adjuster switch adjust ac volts up or down perfectly. The S6 switch does...

Ok, read the document... GOOD READ!! Have the parts ordered to make the Quad Winding fuse mod... Got everything to do 5 Gens for $60.

Yep, that is the one.... It's the first Gen (out of 8 I've had), I've seen with this fuse holder in it. Is it an easy fuse to source? Local Lowes or have to order? I definitely plan to put one in any and all future Gens I find without it!! Thanks Guys... MUCH appreciated!!! :)

Question... What size fuse is supposed to go into the FU2 holder? Right now I just have a piece of Aluminum tubing.. lol For my other MEP-803A I'm keeping, I'm going to add this fuse to the A1. Thanks again for all your help!!

OK... I got it working. This unit has many items that look completely different than any of the other MEP-803A units I have, or have had. Apparently the FU2 fuse is a quick pull type of fuse holder, actually mounted against the A1. It didn't have a fuse in it at all!! ( Ok yes, I'm a dunce...

Ok, when I start with S1 and hold in start longer, - I see the AC voltmeter show 220v, - my meter plugged into the 110v outlets shows 110v As soon as I let go of the S1 from start, it all drops to 22.5v I checked pin 7 on S1, While holding S1 in Start, it shows 21.5v. ( Where is the FU2...

Ok... Newest Update: Unit #1 - Power Switches are correct. Gives good power, but the AC voltmeter is still zero. Leads show zero as well.... I didn't see a troubleshooting path in the manual for the Voltmeter? Unit #2 - Removed the Tobyhanna rebuild remote monitoring plug and wiring. It was...

OK... Unit #1 ... Held down the S1 longer and she fired right up, and ran fine. Ran it for 30 min. Temp at 185deg, 40+psi oil pressure, good power... Only issue is the AC voltmeter doesn't work at all. I shut the unit down, and it restarted no problem. Running smoother now. Unit #3... Did...

Thanks guys... I'm going to remove the "new" Remote Monitoring Port, and put this Gen back to stock. Then see if it starts normal. I'll update with some pics. Thanks!

I'll give it a try holding the start switch longer on Unit #1... For Unit #2, the dead crank works fine and spins the motor over easily... Has two new batteries, and cables tested good for resistance. As I said, It's only when I try to start it.. it starts to spin the starter, then kills...

I bought 4 auction MEP-803A's.... - (Unit #1) Added new fluids, filters, inspected the unit, fixed fuel return line, new batteries, 5-gal clean diesel... Dead cranked fine, no leaks, charged fuel system 4x with 30sec pause between. Then cranked it up with a shot of either in the air intake...