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The linkage will appear normal on the outside even if it's frozen ( due to a sticky metering pump ) on the inside. The rack is not directly connected to the rack, the only connection in the opening position is a spring, so if a pump is sticking the linkage outside the engine pulls on the spring...

Some of these 803's came with an arctic ( diesel powered ) coolant heater installed. I've removed and sold 2 of them being that they are not needed here in New England. Perhaps you could keep your eyes out for one to become available? That could be run for a while after an outage occurs, prior...

Just for the hell of it, unplug the fault indicator panel and see how the machine performs.

Pretty sure I bought parts to fix a couple and ended up finding replacements, perhaps I should revisit fixing them for shelf stock!

Where is that mess connected, to the float control module mounted down beside the fuel tank? If so, it looks like maybe someone else already attempted to bypass it. If they did it correctly and it is still causing problems, your float module may be the problem.... seen that twice before.

Don't get hung up on the 100A main breaker rating Vs the 50A breaker feeding your equipment. Go to the top of the Generator forum and read the 002 003 Main Breaker sticky that Sewerzeuk posted long ago. It explains the difference between the breakers in these machines and your typical thermal...

When backfeeding into the 50A breaker in the house, are you able to load up the generator and get it up to 100% without tripping the breaker? This is assuming the house has 240V loads big enough.... What gage and length is the wire you have running from the generator out to the garage? Do you...

Ah, well that's not quite how I interpreted your original post. If it's fine with no load and the breaker turned on, then frayed wires isn't the problem. A proper operating 003 will just barely start most 5hp motors without popping the breaker, depending on how much load it present at start up...

Agree with everything above. Sounds like a frayed wire shorting to the chassis, and yes the frame could very well become energized and be dangerous to touch. Since this only happens with the breaker closed I would open the side of the AC reconnect box and check for mouse damage. Then look at...

Looking at Kurt's description of S5, I'm confused as far as you saying S5 is not getting 24V. Sounds like the contactor gets +24 to the X connection through K20 and gets its ground from S5, so that makes me assume you should not expect to have 24V power at S5, but rather continuity to chassis...

Does the contactor close while holding the switch up? I assume no? Have you tested either the old or new contactor per the TM by applying ground and 24v to the small terminals? If so what was the result? If not... test that first to confirm the contactor is functional. Are you also only getting...

No worries at all, reading some of these schematics can be intimidating at the very least. I can barely scratch the surface compared to some of the electrical guys here! Good luck, hopefully you get it fixed up, if not we're all here to try to help.

Ok, in the schematic it looks like positions 6,4,8 and 2 are all jumped together. Take a multi meter and look for continuity between all the even numbered positions. With 1 jumper missing I suspect you will have 2 groups of 2 connections each and the jumper is meant to connect those 2 groups...

Look at the wiring schematic. it will show multiple jumpered connections within the switch. Check each jumpered connection and see which one you're missing.

OMG, that seems like a bad idea, being in an enclosure that small. You should see if you can modify that enclosure with fully removable or hinged sides for service access! Working on sets with the AASK is bad enough, let alone stuffed into a tiny house!

Choose based on condition, not solely on hours. You often can't trust the hour meter anyway. I personally think machines with 500-1000-1500 hours often run better than those with 2, 25, 50 hours. They have been broken in and they were used a bit as opposed to those with no hours that either sat...

If the alternator isn't working your batteries should be slowly depleting while you're running. Are you having to charge the batteries with an external charger to be able to start it after it has run a while? Rather than testing at the regulator, with the engine running, test at the Batt+ post...

Can you elaborate on the DC power conditions. Sounds like you have the set running but have no DC power at F1 or F2 but there is power at the DC circuit breaker, and the fault indicator panel isn't working? I assume you started it normally from S1 ??

Regarding the coolant recovery tank, you can look around on this site for details but the best solution is to go on Ebay and buy a coolant recovery tank for a late 80's Suzuki Samurai. It will fit right in place of the original, all you have to do is modify the hose slightly because the...

If you're in need of accessory parts for your trailered generator, send me a PM with what you are looking for. I have brand new ground rod sets, fuel hoses ( still coiled up) , pullers and drivers, ground clamps. and you wouldn't believe how many sledge hammers and rod pullers I've sent to the...