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I worked for Fermont for 38 years as their test engineer we never had the batteries in the sets we always started the sets with slave batteries. Just make sure you leave the batteries plugged in for a while after starting to recharge the batteries. I hope that's expert enough for you.

You are wrong, there is nothing wrong with starting the set and then removing the batteries. Only thing I would caution is that if the set shuts down on a fault you will have no dc to light the fault indicator after shutdown.

I understand what you need And I have some, I actually have both plug and receptacle brand new.

I've got several of the plugs. PM me.

If one can In production we would reject the inverter and send it back for repair install another and keep going

I have seen it If you look at the schematic you can bypass the overload contacts that open the contactor with the battleshort switch. It just reroutes the ground path to the contactor.

If the contactor only closes with batleshort switch on the it's probably the K8 in the inverter

The begining of this thread was about trying to overload the genset with resistive load. You cant get to the overload current trip point with resistive load only, period. 5.5 kw is the spec limit for kW load, nothing to do with reactive load, current load or overload. MIL DTL 53133 says to...

Tape up the battery cables in the set and use the slave connector on the outside of the set.

Spec limits on Max power (kW) is 110% of rated kW on all TQG sets. Over load is current. So if you can get 5.5 kW then the set is operating as it was designed to.

You cant increase the current that high using resistive load only or the engine will stall. You need reactive load to do that.

(anything over 130% the trip time is inversely proportional to time.) I meant over 130%, trip current is inversely proportional to time.

I hate to tell you but you now know nothing. The overload trip is over current if you use a resistive load bank then you would have to put to much resistive load on the set to get to the over current level. The over current trip point is 130% of rated current and the relay trips in 8 +/- 2...

If you want to buy 4 brand new load terminals, mounting hardware, nuts and retaining clips pm me

P/n 69-692-6 The last dash number is the size, 69-692 is the part number for all load studs on all gen sets. then a dash for size.

Everyone here is willing and in most cases able to help. The idea here is to learn by doing with direction from the masses of knowledge here. Doing is the best way to learn your machine. As you trouble shoot, you post your findings here and we will help and yes we have parts IF you need them...

Going back several years ago Fermont didn't exist either, they were DRS and still building 100 and 200 kW TQG's. The Cat engine they were using was being discontinued and the government asked DRS to come up with a FIKE (field install kit engine) which meant that DRS would come up with an engine...

Dont think hitting it with a hammer is a real fix but OK

Im in Connecticut, I dont travel but I do have parts. What contactor do you have in this set, (brand), Contact Industries, or Ametek? You probably dont have a bad switch you have a bad contactor. Ametek is known for this issue. I have several Contact Industries contactors.

GAC's web site adjustment of the start stop knob is incorrect. Other than that the procedure does include things that I never wrote in the original procedure, when we manufactured some 25 thousand 3 kW's we had new engines that we knew had the spring in the proper hole etc.