Looking for a bit of guidance on mep-802a.

[Renojxd]

Picked the set up with 3600 hours. Brought it home and engine starts no problem.

Things I have done:
Quad fuse mod
Measured voltage at K1 a1,b1,c1 (120/240v)
Installed diode at s5 between 2-5


Was getting 120v at the convenience outlet. Closed s5 and it won’t hold. Removed k1, contacts we’re hot at one time. Clean contacts and reinstalled k1. Same problem s5 won’t hold.
I began to investigate tb2. I found one lead from the s8 lo position went to tb2 L3. I disconnected the lead that came from s8 Lo and reattached it to N at tb2.
Now when the generator starts I immediately get an over voltage alarm and the engine shuts down.

 

[Ray70]

Are you saying there was a miswire at TB2 that you "corrected" and now you get the overvolt fault?
I would put the wire back for now if the gen was running ok before and fix the issue with the K1 contactor first.
Try testing K1 using the instructions in the TM, which essentially have you put 24V and ground into K1 to test it without the switch.
If that works, check the switch wiring, the orientation if the diode on the back and the condition of that diode.

 

[Renojxd]

Yes the contactor s5 would not stay closed at first due to what look like a fault the way it was wired at tb2.
I swapped the wiring on tb2.
Now I get the over voltage alarm.

I will test k1.

 

[Light in the Dark]

Well did the original way it was wired, match what the wiring diagram shows?

 

[Renojxd]

No it didn’t. Now it’s wired like the diagram says but I get the over voltage alarm now.

 

[Light in the Dark]

OK so it was miswired... that tells me if 1 wire is off, there is more than likely more than one wire in the wrong position. I think you need to start double checking all of the wires on the switches and look for any that appear to be strange (the wires all flow and form to exact length and position... best dead giveaway of an incorrectly positioned wires are extra length, weird bumps/bends to take up slack, etc).

 

[Guyfang]

It could be mis wired, to get rid of the over voltage fault, and make K1 work. So the question is, what voltage IS it putting out?
Measured voltage at K1 a1,b1,c1 (120/240v) So measure again, with the TB2 wired correctly. What you got?

 

[Renojxd]

It could be mis wired, to get rid of the over voltage fault, and make K1 work. So the question is, what voltage IS it putting out?
Measured voltage at K1 a1,b1,c1 (120/240v) So measure again, with the TB2 wired correctly. What you got?

I would like to check voltage now but i can’t keep the engine running. Is it ok to use battle short?

 

[Guyfang]

For short time periods. BUT NOT LONG!!