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Correct, towards the control cube. Only down side is that you may have to either remove some sheet metal or remove the IP to get the fitting in. The vertical end is usually touching the underside of the sheet metal when installed. Is the end of your return hose a Female JIC? I can't recall...

You're correct, that fitting on top of the IP is supposed to be a Tee with the return line pointing forward. It's a flare fitting, 1/4" tube I believe. You can probably find it at a good auto parts store, if not I have them.

If your overflow bottle repair doesn't hold, a cheap solution is to buy the bottle for a Suzuki Samauri on ebay. Just have to alter the bottle overflow hose routing a little. You can cut yourself a new gasket ( if desired ) from flat sheet Red SBR rubber or silicone sheet. For the exhaust...

I think a slight tweak to the governor sensitivity will get you right where you want to be, but a 3hz droop at 110% doesn't sound that bad to me, but you may be able to get it a little better. Follow the TM Kurt referenced and go as far as you can without causing the generator speed to hunt up...

Have you performed the governor droop adjustment procedure in the TM? and also do you set your initial no load Hz at 61 - 61.5 per the Operation manual? if so you should have no problem keeping the Hz within spec. With both AC units running, what is your % Load? if you are around 75% there is...

What are you trying to accomplish with this project? Are you looking for something that would maintain Hz more accurately than the mechanical governor, to keep the Hz precisely stable with no droop at all? Only asking because a well adjusted governor should keep you rock solid up to around 50%...

If you run it hard a few more times and the smoke still doesn't clear up there could be an issue with the metering pump timing or cylinder balancing. But put a few hours on it to wear in your new rings and burn out anything left in the muffler, then reassess the smoke situation.

Good job Shane, that's what I like to see! You guys took the time and did your research, found info on a similar thread, investigated and found your problem! Excellent progress so far. Now you just need to free up or replace that sticky switch. I saw that the original switch was discontinued...

Hi Shane, sorry to hear you're having issues with the 005, hope it's been good to you otherwise! For starters, don't put a screwdriver across the 2 large battery studs on the starter, you'll get a big surprise! ( and probably melt your screwdriver ) The problem could possibly be a dirty starter...

Agreed... I'm not overly impressed with them either, but I bought it along with several 802's and an 803 from a private "collector" in PA. I just wanted to try one out and see what they are all about, but now I figure I may as well hang on to it incase I need something small to transport or to...

Yes, Jay Rizzler.... awesome guy and so are his yard guys. They will load anything onto anything without issue. Look for the crushed entrance on the left side of the street if coming in off Philadelphia Ave. Also... super importantly... make sure you are on Rt 433 Sunset Pike, not Sunset St...

Back to the OP's spare parts. One thing I would suggest on your spare AC VR's, if they are used and you have not personally seen then functioning, I would swap them into your machine and give them a good test. There are 3 transistors on them that will quickly fail if the donor machine had any...

The other interesting thing is that this machine has just over 100 original hours on it and someone at some point covered every single electrical connection inside it with clear silicone. Seems like someone already had an inkling that there was a moisture related issue somewhere, they just went...

(y) Gotta say Kurt, you continue to amaze me! Who would have thought.... moisture in pots! I saw your board removal instructions and it sounds like I have a game plan! If I recall correctly, I think this machine had the same issue when I first got it ( had been stored outside at the seller's...

If I recall correctly, wires 1 and 2 don't matter as far as orientation because it it AC voltage coming into the regulator. You may find more info in the charging circuit sticky at the top of the Generator forum.

Interesting, so was it the Fault control panel that you dried out, or just the control box in general? My 831 was running fine ( other than a governor controller issue that Kurt is generously assisting me with ) a couple days ago, but today it starts and 4 seconds later trips the overload...

Thanks for the kind words L.I.T.D !(y) Everyone has been very happy with them.

Hello Everyone, About a year or more ago I began machining a true drop-in fuel filter base to convert the Mep-002 through Mep-005 generators from canister to spin on filters. Since then I have tried several times to locate my own post using the Google search function and have found that due to...

Sounds like you are on your way to success, but if you need anything verified visually, I have the same vintage Hollingsworth 005 here in my yard.... with a likewise goo dripping Thermal Watt converter ( I read Guy's correction ) (y) if You need anything checked out.

What do I see in Picture #8 of post 17? Looks like an aftermarket voltage regulator.