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For starters I'd suggest the following. 1) If the set has the Fuse Mod check to be sure the fuse is installed and that it's good. 1) Measure the AC Voltage at the outlet while the set is running. What's the AC Voltage? 2) Measure the AC Voltage at the outlet while the set is running and...

Could someone measure the AC Frequency of the signal from the MPU to the Electronic Governor Controller on their 804 while it's running? It can be measured at the electronic Governor Controller across terminals 16 & 17. Many thanks!

You have the Fuse Mod which is good. You have the original factory AC Voltage Regulator.

Excellent pics. They certainly help :)

I've been actively working on this to provide the MEP community a solution for the hard to find Float Switches and Fuel Level senders. Today I bench tested a breadboard version and it worked well. :) Ording some PCB's Monday to build a few prototypes and fully test in my 802A. Assuming the...

The OP sensor is a 3 wire sensor. The DCS provides it 5 VDC and ground to power it. It's ratio metric output varies from 0.5 VDC at 0 PSI to 4.5 VDC at 100 PSI. Maybe put a meter on its output terminal C and monitor its output voltage to see if it's incorrect?

Was the -4 reading on the DCS after the engine stopped?

You should have good continuity, zero-ish ohms, between all the points in my diagram. If you don't then you need to dig into the wiring path between the two points.

M8 terminal 1 to J6-7 is wire 162A. P6-7 to S8-44 is wire 162B. If you are measuring 120 ohms, then you may have a bad splice or poor connection between the contacts J6-7 and P6-7 ..............Wire 162A.........................................Wire 162B...

S8 is similar to S6 on how the terminals are arranged. All odd numberer terminals on one side and evens on the other. Here is a shot of some of S8's odd terminals.

To check the resistance of any of those resistors you need to disconnect the wire(s) from one end of the resistor first. S6 "odd" Terminals S6 "even" terminals

I attached some display pics for comparison to yours. Just happened to run it today for testing a DCS. (Ignore the 114 V AC in the first pic. I hadn't adjusted the voltage regulator yet) My 1030 with ~ 50% load on it after running a minute or two. Coolant temp 123F with 60 PSI Oil Pressure...

You'd check the current at M8 using your clamp on ammeter. The right meter in your pic. Clamp it around ONE of the two wires going to M8. It doesn't matter which one. Like this.. Set the meter to 40 AMP AC setting Zero the meter is necessary. Be sure the generators AM-VM switch is in the 3...

Did you see if there was current flowing through the Load meter? If so how much?

Troubleshoot. Don't throw parts at the problem. Put a DMM in series with M8 to measure the current thru it and see if it jives with what M8 displays for load.

No. The %Load meter M8 is not connected to +24 volts or chassis ground. The %Load meter is an AC Current meter. 0-1 Amp Full Scale In a nutshell... The 3 Current Transformers in CT assembly each output a current that's proportional to the load they are sensing on the 3 legs of the generator...

On one side of the switch the terminals are odd numbered and the terminals on the other side are even numbered.

Have you reset the Overspeed switch?