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The interesting problem is that its disconnecting the load even with the battle short on. Something is breaking the current flow from the interrupter switch to the K1 contactor. Usually with a bad burden resistor, you will get an overload fault and is easily bypassed by the battle short. I still...

Something your missing when you removed K8. K8 wouldn't effect the 24volt system. Did you check CB1 (DC breaker) and make sure your battle short is not on. DC powers goes to CB1 then emergency stop then to the master switch.

I'm here to help. Just because it has 1400 hours on it doesn't mean someone hasn't been monkeying around in there. I had a reverse connection on s8 one time, that was causing an overload fault and it had 2500 hours on it. I would swap the overload relay first just because that is the only common...

I would look at the wiring diagram and make sure everything is hooked to S8, K1, and S5 correctly. I would first try to swap the overload relay first because the battle short bypasses that internally with a relay. Something is sending the signal for the overload and disconnecting the load at K1...

Did you notice if the short circuit light came on when you lost power with the battle short on. With the battle short on it still passes through the overload relay so if something is going on inside the relay it could cause your problem. A short circuit is the only thing the battle short will...

I wanted to let you know that I just finished up on a 803a that had previous work completed by someone else and I was having overload and voltage gauge issues. Took me about a week but I used the wiring diagram and traced ever wire that ran from the burden resistors, K8, S8 and S6. Found that 2...

TNriverjet did you ever get the generator to not trip the overload?

My experience with tier 2 resets have been excellent. Pretty much everything is new; motor, generator head bearing, relays, all the switches, fuel pumps, etc. All the items that could wear out are replaced.

Sounds like s8 reconnection switch with corroded contacts. You have to work it left to right sometimes 100+ times while spraying electrical cleaner to clean the contacts. Usually if a winding is shorted, you wont get any output.

Link for the burden resistor if you need one. http://www.mouser.com/ProductDetail/Vishay/FSOT2011E7R500JE/?qs=%2fha2pyFaduhCPRwebPKtkfhQJyJNJP1Y4QMMNcBPyDfVIp1fLMwycA%3d%3d Last time I had to order some, it was a 4 week lead time so I bought several if you need one.

LOL! that is K 8 in the post above, it's not supposed to be a smiley face with shades.

CR2 is just a diode so you can check that without unsoldering anything (but that doesn't have anything to do with K8). R10-R13 are the ones that lead to k8 and it's easier to just unsolder the left side on R10-R12, then you can test each one. R14 can be tested without de-soldering because it...

This has been discussed and debated a bunch. If you're using 4 wire hookup to the house with an independent ground I would just unbound them. To be honest, I've never un-bonded the unit I set up at my parents house because I forgot when I first installed and never went back to redo.

You'll have to un-solder one side of the burden resistors. The TM does not say to but I can never get an accurate reading without un-soldering. I may have an extra K8 I could send you for testing. I've never had a K8 fail, it is usually a burden resistor or dirty connection. First time for...

I still think you have a dirty connection causing the problem but you can also de-solder the burden resistors and check them with and ohm meter. They are part of the control circuitry but I've never had any go bad to show O/L. I've had a couple go bad that would set off the short circuit...

There is a connection board located under the old rat nest, make sure all those connections are tight and not corroded. Rat urine will cause serious corrosion. I had an 802a that had 1 loose connection on that board, that caused a O/L and almost melted the connector. Also spray the AM/VM switch...

Its about 45 seconds before it trips. Do the burden resistors correlate to the problem I'm having with the percent load gauge?

Just got in a nice 803a and was load testing the unit. As I was increasing the load, the percent load gauge barely moved and after approximately 60 seconds the interrupter tripped and the overload indicator lite up. The amperage on both legs were 43 amps and the percent load gauge was reading...