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Absolutely necessary.
Do NOT run the generator without the Fuse Mod installed.
Running without it you risk the AC Voltage Regulator shorting out and burning up the generator head.
For the 802A part lookup you'll want to use TM 9-6115-641-24P
Here are the parts for the Oil Pressure sender (item 7) area in that TM
The following page lists the part numbers
If you then search the TM for "02504" you'll find the NSN number 6620-01-128-3053
Then, if you go to...
Is the mag pickup (MPU) adjusted properly and providing 2-3 volts AC across GC terminals 16 & 17 when dead cranking the engine?
According to the info below the DC voltage across GC terminals 9 & 10 may give a clue. This is the voltage sent to the actuator to control engine RPM.
When initially...
It's S6 & S8 for that issue. Need to pop the top off the AC compartment to get to the back of S8.
Along the sides of S6 and S8 are small openings by each terminal screw to spray the Deoxit in.
Below is a pic with arrows pointing to two of the many openings in S8.
OK, that's indicating either the battery(s) are not charged/bad OR something in the path of getting battery voltage to S19A2 is failing.
Measure the DC voltage at the following points with your meters Negative lead on TP31 (chassis ground), E-STOP pulled out and S1 in START
1) Voltage at S19-A2...
It has both input and output protection by way of a pair of fuses. It does not utilize the power from the Quad winding so it's not affected by Quad winding voltage spikes. Also the VR is switched out of the circuit during Flashing.
My understanding is that during cranking the Quad winding in the gen head can output some voltage spikes that exceed the PRV rating of the diodes in the VR causing them to short out. Exactly how I don't know. The flashing circuit is voltage limited by R14 and this only supplies voltage to the...
When in single phase mode only CT1-C is used to drive the %Current Meter.
The path highlighted in GREEN shows the paths from CT1-C to M4.
The last leg of the connection are the RED and BLUE lines. These are the connections made internal to S8 depending on if S8 is in 1 Phase L3-L1 or 1 Phase...
You could add some appropriate outlets to the 803 to connect your "load bank" heaters to.
The output lugs on the 803 have lots of room for conductors.
There should be no need to disconnect the wiring from the 803 to the transfer switch during load testing.
It's AC current "in" by way of the wires passing through each CT opening. They created a magnetic field that the coils inside the CT detect creating an AC current output. The AC output current is proportional to the current in the leads passing through the CT openings.
The Percent Load Meter...
Also be sure Battle Short switch is turned off.
See if the contacts inside of Relay K16 move as S1 is moved from Stop to Prime/Run. They should.
*edit
K16 is the Crank Disconnect relay. If S14 is bad/missing K16 will not move internally causing a no crank from S1 situation.
If the set has a...
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