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Guy, I have the cover off my 802A, and my A9 module wires have numbers on them (magnifying glass size). The tie wrap on the generator side is labeled with the plug number P-15, the float side tie wrap J-12. The wires on the float side, going to the J-12 plug are numbered 1F, 2F, 3F, 4F. The...

If you disconnect all the wires going to the exciter and voltage regulator (tape them off individually) you wont damage the generator. The generator will not produce any power without excitation.

Here is an update on my Fernco diesel soak test. I placed the remnants of my Fernco coupling trimming in a jar of diesel on 18 March 2018. I just found the jar, while looking for some other items in my shop. These parts have been submerged in diesel for almost 6 month. The plastic has hardened...

The motor shops dip the windings into a polyester resin, then bake the winding to cure the resin. For severe service the winding is soaked in the resin under a vacuum, then under pressure, called VPI - vacuum pressure impregnation. That is what I would spec for your windings. There are also...

I am back in town, and plan to get the set up and running in the next two weeks. I tested all the electric components with a 24v power supply, and all relays, lights, fuel pumps etc. work as they should. Now need to get batteries, fill the oil, and then start flushing the cooling system. I found...

I get all my stainless fasteners from this place https://www.albanycountyfasteners.com . They have just about anything you need in stainless

I get all my stainless fasteners from this place https://www.albanycountyfasteners.com . They have just about anything you need in stainless. Oops, posted in the wrong thread.

I just ordered three sets from Rock Auto. $5.34 for all three, but $8.95 for shipping. Grrrr.

Depending on the type of charger you have, the inrush current of your battery charger could be too high (sort of like starting a large motor). What is the current draw of the charger, and does it also show the inrush current? Are your 40 amps at the 110 volt setting?

I suspect the crud was silicates. I could squish it, and it dissolved in boiling water. I connected the cooling system to my washing machine hot water faucet, and ran lots of hot water to flush out most of the crud. I will flush the system several more times before filling it with antifreeze...

Had some more time to work on the set again. Cleaned up the fuel tank, replaced all fuel lines, installed a new "FERNCO" coupling and took "Light in the Dark's" advice and replaced the thermostat. Glad I did. The picture of the thermostat and housing are self explanatory. Amazing what shows up...

I decided to pull off the radiator hoses today, since I heard and felt a significant "crunch" when I squeezed the hoses. Turned out the springs inside the hoses were rotted away. Lucky I caught that, before circulating spring particles through the cooling system. (The cooling system was drained...

According to the FERNCO website, the fittings are made from PVC. Their chemical resistance chart does not include Diesel, but they marked Kerosene as "not recommended". Since this coupling does not hold any pressure, I don't think it will be an issue. I cut up the leftover piece I had from my...

Had some more time to work on the set today. Replaced the upper well nut, and replaced the fuel return hose. I had to fish the fitting in with a wire. My arm made it into the tank, but could not get to the fitting. Those brass & O-ring fittings should last for the life of the set. I used some...

I found the Fernco 1070-44 works. You just have to trim the length somewhat. $11 at the big orange home center.

Apologies for causing some confusion here. I misread that your machine is a 003A. I read 803A. 36 ohms is correct.

Yes, I was referring to the exciter field wires that go from the A1 VR terminals 5&6 down to the exciter stator. 35 ohms seems high. The TM shows 10.54 to 14.26 ohms for the stator leads in table 4.1.

I am relatively new to the MEP-802, but here are some thoughts. When you are cranking (with the field flash relay energized) are you getting any voltage on the QUAD windings? Any chance you have a shorted diode on the VR, and are getting AC voltage into the semiconductors? Any chance you have a...

No, it didn't, but does now. The first thing I did was check the resistance of the Quad winding. All was good, so I added the fuse and varistor. If the Quad winding would have been bad, that would have been a wallet buster! To rewind a stator is about U$D 950.00 definitely not cheap.