802 tripping on overload

[spuddle]

Hi all, ive read several threads about this. Still trying to figure things out here. At about 2500 watts it starts tripping the overload, reading about 40% load on the gage. If i enable battleshort it will not trip, but the overload light turns on. And remains on.

Looking for some tips to try and rectify this. Is this the k8 relay (ci?) being dirty and just needs cleaned? I seem to see a lot of problems with this. And im kind of at a loss here. All switches look good, wires look good, ac ci switch seems to work fine. Overload resets when pushing the button and immediately reconnects when flip the switch.

Unit has 220 hours on it. I do live in a very humid environment as well

EDIT: And now after running for 13 hours it wouldn't shut down. I dont know if this is related. Had to use the off switch in the engine bay and wait for it to run out of fuel to shut down. The run switch did nothing but turn power off to the gauges.

TIA

 

[kloppk]

Check out this thread. Lots of good info on things to test to track down the cause of a false overload.
False Overload Issues

 

[spuddle]

Check out this thread. Lots of good info on things to test to track down the cause of a false overload.
False Overload Issues

Thank you. I am working through this thread now. Hopefully this will shine some light for me.

Any suggestions of why the unit wouldn't shut down? Or where to start looking?

 

[Guyfang]

One thing at a time. Sometimes you get lucky and both problems may get corrected for only one fault.

Is this set new to you? Have you ever seen it work right? For longer periods? Have you fixed anything of late? Are you using the TM's to troubleshoot?

 

[spuddle]

This is new to me. I have 2 of them. Only really played with this one so far. This is the first real load testing of it. I ran on the convenience plug for a few hours and never had an issue. This is the first time running off the terminal board.

They get fired up once a month at least and run for about 10-15 minutes, and i exercise the ci as ice read in here to make sure to do so they dont stick.

Was redoing my solar system, and has the house running off the gen just fine all day yesterday, then when got everything hooked back up and started charging batteries is when i started running into it tripping the overload. Started originally tripping around 4000 watts, then every time it tripped i had to keep reducing the load down to about 2000 before it stopped tripping, thats when i hit the battleshort and was able to crank it back up to around 4000.

Then the end of the night, i opened the ci, turned battleshort off and tried to shut it down, which the main switch did nothing. Havent started it today so far

EDIT: Yes i am using the plethora of manuals for these.

 

[Guyfang]

Do you have a load bank? Or something something you could use to load the gen set to rated load, besides the battery charging setup? If so, disconnect the battery charging set up. Hook something else up to the set and load the set to rated load. Will it run right?

Was redoing my solar system, and has the house running off the gen just fine all day yesterday, then when got everything hooked back up and started charging batteries is when i started running into it tripping the overload.

I say this, so that you can eliminate the possibility that something got hooked up wrong after the work on the solar system. Normally we would start telling you to clean the S8 switch with contact cleaner. That seems to be what helps out with most of the overload problems. But over the years I have found that when something worked before I did work on it, and didn't work later, I hooked up something wrong. Food for thought.

 

[spuddle]

Unfortunately, i do not have a load bank. Ive been wanting to get one for my 26kw diesel, but havent had the funds, nor would that work for these i dont think

 

[Guyfang]

Then maybe you need to try cleaning the S8 switch. That could also be your problem.

 

[2Pbfeet]

Unfortunately, i do not have a load bank. Ive been wanting to get one for my 26kw diesel, but havent had the funds, nor would that work for these i dont think

There's always rescuing/repurposing an old electric stove, or several electric dryers elements with new fans, or looking for some "scratch & dent" electric heaters. E.g. I rewired a 10kW heater with three elements to give me a DIY load bank with 1.6/3.3/4.9/6.6/10kW. Not as compact as a purpose built load bank, but it works. Total cost less than $100.

All the best, 2PbFeet