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The 10xx fuel level sensors are different from the 80x versions.
The 10xx sensors are a 3 wire sensor. Ground, power and a DC voltage output proportional to the fuel level. 0.5 volts for empty and 4.5 volts for full as I recall.
Replacements were available on ebay. I've bought both versions...
I hear you about the exhaust!
For TB6 you could cut the 3 factory wire harness wires as close to TB6 as possible and then splice them to my wire harness 3 wires for TB6.
Splice....
My TB6-1 wire to factory wire 115B16
My TB6-2 wire to factory wire 116B16
My TB6-3 wire to factory wire 117B16...
Jumpering terminals 5 & 6 on S5 will cause the contactor to stay closed.
*** Caution *** Doing so bypasses the Overload and Short Circuit protections *** Caution ***
With the set stopped unplug P6 from under the control cube and then plug it back it.
To unplug P6 you'll need to turn its locking collar to unlock it from J6 and help back it out of J6.
Reverse for plugging back it. Be sure locking collar is all the way locked when done.
The signals to/from the...
OK, getting power to lugs indicates the contactor is not stuck and is closing.
The switch usually don't go bad. Likely something else.
Was this generator previously working OK and providing power to the lugs for you?
Does S5 have the Diode installed on it like this in this orientation?
The DCS in the MEP-10xx reads the DC voltage from the sensor and then displays the fuel level on it's LCD display panel.
Here is a 1030 Fuel Level Sensor. No floats, just a tube.
The 10xx use a high tech ultrasonic level measuring technique to determine the fuel level with no moving parts. It outputs a DC voltage proportional to the fuel level.
I've been thinking about this one. It strange they used three different fuel level measuring systems, one for the gauge, a second for Aux Fuel and a third for Low Fuel. A single level sensor with a tiny bit of smarts could accomplish all three functions.
The MEP-10xx sets use a single...
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