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A little progress today, unboxed the new stator going into one of my sets and rang out the windings and tested for shorts to ground.....all tested good. A little clean up and some paint and it will be ready to install. Also, trying to work smarter not harder so I had a couple of roller stands...

TB2 cleaned up, new stainless hardware and ready for install. I didn't know that the metal mounting bracket is a copper alloy plate. There was substantial galvanic corrosion between this plate and the case when I removed it. I will be using stainless bolts and nuts and applying a thin coating...

Guyfang, No offense taken at all. I take all input from you as constructive and informative. I hold your opinion and guidance in the highest regard always. I am using this set as a learning experience. I have thought from pretty early on that there was an issue with the windings. I wanted to...

Yes, I had mentioned delving into K1 before but didn't get to it. This unit has corrosion problems and I am working through them bit by bit. I look upon this as an educational experience more than an exercise in frustration. I am both mechanically and electrically/electronically trained so...

Another nice day today, 50's and calm. Finished cleaning up TB2 load terminals, waiting on some stainless hardware being delivered tomorrow to use on the varistors to reinstall it. Reinstalled TB4 and reconnected the generator wires T1- T12, then reconnected all the other wires according to...

Had another decent day today so I went back to the generator. Unbolted the current transformer from the back of the housing and disconnected primary leads from the terminal board and cleaned them, tidied up the primary windings with a couple of zip ties, then pulled the terminal board TB3 out...

Very good point! I will do that.

Stopped by my local Harbor Freight store to pick up a few things including zip ties for the harness and found these (stainless) for cleaning up terminals and terminal boards along with electronic parts spray cleaner. They fit the dremel tool extension ( like a dentists drill)and should make it...

Ok will do. Thanks!

Well, spent a little more time on the 803 today, checking and cleaning connections and checking wire numbers. Breezy and cold but sunny.(good lighting) I pulled connections at J5-P5, J6-P6 and J7-P7 apart and found some corrosion in J7-P7.( see pic) Cleaned them up with cleaner and small...

Thanks, I read the post a while ago where you explained that. It spurred me to go and recheck all my connections on the defective unit. I replaced both S6 and S8 in this unit last summer, wiring them per the schematic, and had a working unit right beside it to compare. I will go back over it...

Will do.

Made my voltage measurements today. All measurements taken using a Fluke 29 Series II digital multimeter. My measurements with genset off and resistors isolated: R10= 7.2 ohms R11= 7.6 ohms...

Thanks, I will measure and record the voltages as you indicate. The number of turns through the current transformers are correct, I checked the count but haven't yet measured the output of each while running. I will check back tomorrow with my findings.

Thanks, don't sweat it, I'm sure its solid. I don't think its that part either. There is something triggering the overload fault/ tripping the breaker. The winds have picked up here significantly so my work with the set is concluded for today. I will perform further trouble shooting tomorrow...

Update: So far, I've replaced S6 and S8 on this set ( that was a while ago) Wired each following the schematics,( as recommended by Guyfang) and is the proper way to do it so a problem is not duplicated. The other day, I replaced the overload/short circuit relay with a different one from a...

Just to keep the thread up to date, I installed the new S8 on the 803a but still getting an overload condition and load disconnect after 12 minutes of load using two 5400w dryer elements. This is with battle short OFF. I have not tried with battle short ON and really don't want to as the set...

Well, my new S8 is in the PO BOX. I'll be picking it up tomorrow and attempting an install if the weather isn't blowing snow and rain. This winter weather just keeps lingering on and on here. Will post back with my results of next load test. Update: Picked up the switch but too late in the day...

I agree with exercising the switches.....and also cleaning them which has proven to me that they do get cruddy because they are not sealed and will impede correct functioning of the generator. On both my 803a's cleaning and exercising brought back functions that were not working. I also...

I don't think there's anything wrong with the old style blue plastic S8 switch, it was used for years on many sets and performed fine. For as many times as I'll ever switch it (probably never other than to exercise it once in a while once the set is hooked up) I can't justify the additional cost...