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Q1 and Q2 are in the large bundle of wires that run from the gen head and go to the P5 connector. From the TM it appears the Q1 & Q2 wires from the gen head have wire terminals on them. I can't see my P5 connector well but it looks like it may have a pair of mating contacts on two short wires...

If you can post a picture of the readings on the gauge panel with the set running so we can see the gauges.

The Pre-Heat relay K18 is different between an 802 and an 803.

Interesting... I've experienced the same problem with my 802 at shutdown a few times. Have been shutting it down while slowly releasing the fuel solenoid by hand to prevent the problem.

Have you used your load bank on other sets and do their %Load meters work OK? Have you cleaned contacts 1-6 in P6 and J6? The CT signals go thru those contacts. If K8 was bad it may influence the %Load reading. You might try disconnecting the two wires on K8-2 and connect the two wire lugs...

The LOW FUEL fault should have nothing to do with the fuel level sender. The LOW FUEL is detected by the float switch in the tank. The fuel level sender only provides a signal to the fuel gauge to operate it. I'd suggest grabbing a meter and checking some DC voltages to determine where the...

A number of things come to mind 1) Gen head leads hooked to wrong TB3 terminals 2) Wrong leads from TB3 running thru the CT2 3) Wrong number of turns of wire thru CT2 4) Bad CT 5) other...

Your readings for R12 & R13 indicate a probable contact problem in S8. With S8 set to 120/240 R13 gets hooked in parallel to R12. So when checking the resistance across R12 & R13 you should get virtually the same resistance. Since you aren't and R13 is reading 7.6 ohms this would cause K8 to...

Correct two terminals but B1 is B2 and B2 is B1.

I'll do the same resistance checks on my set with S6 & S8 in the same settings and post up what I measure tomorrow.

Where do those red and blue wires go to after they leave the top of the picture? Those are not in a normal 803.

For starters I'd suggest using your meter and see if there is 24 volts DC present on each of the terminals of the Emergency off switch. If present then check each of the terminals on CB1. If present then check S1 terminals 2,4,6 & 8. If present then put S1 in the Prime/Run position and again...

Can you re-do the current measurement and measure the AC voltage across R11? With 0.19 amps AC thru R11 the voltage across the terminals should be 1.42 volts AC. Here is a diagram of the %Load circuit in 120/240 mode and AMVM set to the 3 o'clock position.

Did you check to be sure the red Emergency Off button is pulled out?

1 A is 133% Load 0.752 A is 100% Load You need to hook your meter in series with the sets %Load meter. At 100% Load the burden resistors should have 5.6 volts AC across each of them. At 133% Load the burden resistors should have 7.5 volts AC across each of them.

Or two 12 volt chargers, one for each battery.

The %Load meter is NOT a voltmeter, it's an ammeter. 1 amp Full Scale. That's why you see very little AC voltage across the terminals.

Those are for 120 VAC. You need something for 24 VDC

By popular demand kits are again available to perform the Gen Head Swap on MEP-831A's! Gen Head Swap Kit