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When running and the is contactor OPEN is the light on AND you can't reset it on the Fault Indicator panel?

:beer:

P7 is PN 206150-1 All the gold plated 18 AWG sockets Contact size 16 female sockets that could go in it can be removed with that tool per the DigiKey website

I believe the extraction tool you need to get the pins out of P7 is:

What tools did you buy? Part numbers.

The first round of printed circuit boards came in yesterday for the Fuel Level Sensor, Fuel Float Switch assembly and A9 Aux Fuel box replacement system. Yesterday I built it up and then wired it to a K19 Low Fuel Relay, a MEP Aux Fuel pump, Fuel Level Sensor and "Fuel Level" meter on the bench...

Ugh.. Going to require digging into the wiring to check the path from pin 8 all the way to the high temp switch plug to find where power is getting to that path.

K15 is the starter cutout relay. That LED should be on when the generator is running indicating the starter is disabled. 26 volts at pin 8... Try this. Unplug the Fault Monitor. Start the engine. Leave the fault monitor plug disconnected. Measure the DC Voltage with respect to chassis ground...

K8 should have detected an overload and opened K1. I agree with DA it may have burned up due a loose connection.

Normally the LOP light is on before you engage the starter. The Fault Indicator will only display 1 Fault, not multiple ones. Electronically the first fault is senses is what it displays. The fault indicators can go bad. I've repaired a few of them out of 831's and 802, 803's, 804's. Every...

@Guyfang can you change the thread title for the OP? When Guy :beer: has a minute, I'm sure he'll update it for you.

Last post was updated so be sure to refresh

Sorry for the slow reply. Helping 4 people simultaneously with generator issues around the US this evening. The START voltage signal comes from S1-7 and goes to TB5 terminal 14. In total terminal 14 will have 4 wires on it. Two on the top screw and two on the bottom screw. The wire numbers...

This is where it gets ugly, trying to locate what's causing CB1 to trip during START.

I saw the meter flash "OL" briefly. That indicates there is more than 10 amps being drawn causing the CB to trip. Don't keep trying, you may blow the fuse in the meter.

Yes

Yes

I watched all 3 videos. After the "fuel pump" one it looks like it NOT due to a primary fuel pump issue or the breaker being slightly overloaded. The voltage on your meter going from 0 to 24 volts is just indicating that the CB tripped. I see your meter can measure current. I'd suggest you...

Your videos worked. Interesting, CB1 pops when you move S1 from Prime/Run to Start. As previously posted you ought to measure the DC current going through CB1 to know for sure if the CB is bad or if something is drawing too much current. That would be the right way to start to track down the...

Does it trip when you shut it down or does it trip when you attempt to start it?