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Good deal! Glad it worked.. (y)

In my case I think I removed a #12 and installed a #14 if I recall correctly. I think I had to step up 2 sizes. I have lots of buttons, but have used up most of the thicker ones. I would need to see what size you need. I don't think I have anything thicker than #12 or #13 left in my pile! Lets...

Check the ammeter for reversed wires on the backside. Reversed wires makes it read discharging instead of charging. Should charge at 10A+ and slowly come down to zero within a few minutes.

With a min. buy of 100 pcs.! rofl Watch it be cheaper to buy a plasma cutter, a welder and a hydraulic bender and fabricate one yourself!

The timing buttons are available on the internet. I also have a variety of them in my stash, but be forewarned, the thicker buttons are most commonly the needed ones ( #14 15 and 16 ) and of course these are the hardest to find and most expensive. The procedure to test is laid out in the TM and...

Well, try reading this post. https://www.steelsoldiers.com/threads/a-tale-of-two-timing-buttons.198352/ I still can't explain why, but I have an ultra low ( 6 ) hour 003, completely untouched since new and had the exact same symptoms as you. I tried everything! testing compression, lapping...

Has this machine always run like this? Or did you ever see it behave "Normally"? As for the parts, you can get the updated head gaskets direct from Cummins for about $15 ea. Also try www.Onanparts.com If you need a valve, also look around on the internet, but do not search under "Mep-003 valve"...

Great, thank you for your interest. Ray.

Something else you may want to consider when finalizing your design: I recently serviced an 002 that I sold to a customer 6 or 8 years ago. He had put it on a Pre-made cart he had found at a yard sale. The cart was designed to move pipe / conduit around in a warehouse and it was exactly the...

I agree with Scoobyshep. I don't trust that alternator setup, but maybe it's just because I'm not familiar with it. Aftermarket AVR's can be had cheap. That SX460 is still available ( Chinese knock off ) for $20 all over the internet. You could probably buy 4 or 5 of them for less than the Delco...

Sounds like you have already decided what you want to do for control system, but if things change, I wonder if this gen would be a good candidate for an SX-460 AVR? I've used them a few times on different military gens and they have worked well every time.

Agree with Guy, dismantle the gen head and report what you find, that should easily allow us to determine what went wrong. Either way it's a mechanical gen failure, nothing caused by you.... although you really should have a full understanding of the machine, how to operate it and how to prep it...

Correct, K1 is the circuit interruptor, buried back in the left corner behind the inner control panel back wall. Have to remove the top cover to access it.

See reply #5, the only breaker on the entire DC side is on the front panel and kills EVERYTHING. So if your panel lights work, the breaker has not popped. Check for 24V at the cannon plug for the pumps. Do you hear any of the pumps in either aux. fuel or prime/run position? You have 3 pumps in...

the 802 should be no different than the 803. Having power on L2 while in 240V single phase mode leads me to suspect something is wired incorrectly. It could even just be the wires crossed at the K1 relay. If it appears to be working correctly other than sending power to L2 instead of L1 I would...

Yes it could be K5 relay. Could also be the S5 switch. Start by checking the switch and it's diode.

Excellent news! Keep making progress. Check your oil level now, then check it again after you have run it a little bit. Keeping an eye out for an increase in oil level and the smell of diesel in the oil. If the level stays constant then your umbrella seals are good. If the level starts to rise...

Forget $2200 for that! If it isn't shown running... assume it doesn't! Saw another one Wed. went for like $1800. ran but was run from an aux. fuel source. Missing fuel lines etc. Can pretty much guarantee any 002/003 currently coming from auction will need the fuel tank steamed and sealed at a...

If you can locate the leak, you can fix it yourself with Permatex plastic tank repair epoxy. Should be in the aisle with the silicone and other sealants at parts store. Make sure it's the one for plastic tanks and plastic radiator tanks. Comes with 2 packets of a black epoxy specially formulated...

If you have 24V from the switch, then look for 24V at the bulb sockets. Also check for ground at your bulb holders. If you have power to the sockets and the bulbs are good there is only one other possibility.... no ground. The only fuse ( circuit breaker ) on the DC control side has to be good...