User Manual Q&AAnswer
Jan 24, 2025 - 08:53 PM
Replacing the GMG MEP-802A Voltage Regulator with the TRC 19580 requires following a set of instructions. Here is a step-by-step guide:
1. Disconnect the generator from all AC loads, including convenience outlet connections and load terminals.
2. Disconnect the negative lead from the battery and secure it away from the battery's negative terminal. Also, disconnect any external connections to the generator's NATO slave connector.
3. Open the generator's control panel door by turning the two ¼ turn fasteners at the top of the access door and carefully lower the door.
4. Label each of the 8 wires connected to the existing (Al) Voltage Regulator using the supplied wire labels or a black "Sharpie" marker.
5. Remove the 4 screws fastening the existing Voltage Regulator to the cabinet wall and discard them. Keep the fuse holder if present.
6. Position the replacement Voltage Regulator and fasten it to the cabinet wall using the 4 supplied mounting screws. If there was a fuse holder, reinstall it before tightening the screws.
7. Attach each of the 8 wires removed and labeled in step 4 to the new Voltage Regulator.
8. Route the two wires at the left end of the regulator along the generator wire harness behind the relays and secure them with the supplied materials.
9. Connect the lead labeled Kl5-l to terminal 1 of the Kl5 relay socket. This will be the only wire on Kl 5-1 terminal.
10. Route the other wire along the factory wire harness and connect the lead labeled M7-I to the I terminal on the Oil Pressure Gauge.
11. Remove the voltage adjustment xxxx from the existing voltage adjustment potentiometer and remove the potentiometer from the front panel. Secure the old potentiometer out of the way.
12. Insert the supplied pre-wired potentiometer in the front panel, aligning its locating pin with the small hole. Secure it with the supplied nut and lock washer.
13. Check that the new potentiometer is in the middle of its operating range. Reinstall the voltage adjusting xxxx with the pointer up and tighten the allen screws to secure it.
14. Close the front cover and secure it with the two ¼ turn fasteners.
15. Set the new AC Voltage Adjust potentiometer fully counter clockwise.
16. Reconnect the battery cable.
17. Start the generator and adjust the output frequency to be 60 +/-1 Hz.
18. Adjust the new AC Voltage Adjust potentiometer to achieve the desired voltage (120, 208, or 240 volts AC) based on the AM/VM switch (S6) and Voltage Phase reconnection switch (S8) settings.
Please note that these instructions are a summary and it is important to refer to the complete manual for the GMG MEP-802A Voltage Regulator for accurate and detailed instructions.
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