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On the start switch there should be 24 volts DC on terminals 2,4,6,8 as long as the Dead Crank is in the NORMAL position, the Emergency OFF button is pulled out and breaker CB1 is not tripped. You can start by checking for 24 volts DC power to those terminals on S1.

Post removed based on the great input from Dewie about these units. (Info I was given was apparently incorrect)

So I assume the set starts but immediately shut down due to an overvoltage fault?

Here is the wiring to the switch The switch is available on the big auction site. $20 or less

It's possible. One of the leads going to the hour meter is +24 volts. If it shorted to the panel it would likely trip the CB1 circuit breaker.

Hopefully you replaced the fuse with the correct current rating. V5 isn't a diode. V5 is a surge suppressor. If you tested it like you would a diode it would appear "bad". I'm sure it's not. You ought to recheck the fuse you replaced next to the voltage regulator. See if it's blown. You may...

As mentioned above remove the lifting rings The access door stays also rattle when closed. I put small pieces of of rubber tube at the end of the tracks to apply pressure to the ends of the stays when the doors are closed to stop their rattling.

Exactly correct

I believe the -13 TM for the 831A is incorrect in showing the FL1 switch as normally closed. When the fuel tank is filled FL1 would be open, not closed Adding a jumper from J11-1 to J11-2 would actually constantly signal a Low Fuel situation, not bypass it.

It may be a stuck float. You may be able to reach into the tank thru the fuel filler and free the float. Had that happen to one of my 831's. If you can't get your arm in there you may be able to use a flashlight to see and something else to free the float.

PM sent

When you start the set and hold S1 in the START position you ought to get ~120 VAC at the convenience outlet and see normal voltage on the sets AC voltmeter. If you do that confirms the generator will put out power and the flashing function is working. When a set is running normally and with no...

I built a simple cart out of 4 pieces of 2x6, 1/4" bolts and 4 casters. Works great for wheeling it around my garage and outside when I need to use it. The 802 "locks" onto it and can't slide off.

Yes that's a good sign!

The set should show AC voltage on the meter when you start it and hold the main switch (S1) in the START position after it starts. When you release S1 to the Prime/Run position the AC output will cease if the fuse is blown. Holding S1 in the START position causes the set to Flash the generator...

Glad to help you out!

For now install the jumper knowing the risk. Use the electric start and close the contactor so you can charge your battery bank for now. We can address another way to do the test later.

When you have time and you've charged you batteries please do the following test. Leaving S1 in the STOP position lift the actuator off the magnet. Press the compression relief lever. Pull start the set. Measure the AC voltage across the A & B terminals on the Governor Controller. Shut the...

Weird....

In a pinch you can bypass all the safety systems by installing a jumper wire between S5-5 and chassis ground. This will allow you to close the contactor by using S5. **** Doing so will prevent the set from opening the contactor due to any fault **** Proceed at your own risk