Machinetools1, your wiring is a lot cleaner than what mine was, mine looked like a rats nest and had the relays and a few other things just laying on the floor, I cut out about 20 feet of surplus wire and went to work with some loom material, loom clips and zip ties to clean it up, there were about 25 loose screws mixed in with all the wiring, I found several of the wires for the AC and the DC loose, if you have something loose inside the converter then its worth looking into, my first inverter/charger failed after the first year so I pulled it out and took it apart, there are capacitors inside and they will bite real hard if you touch them, there was a group of voltage regulators and half of them were burnt, I called the manufacture and talked to their customer service and right off the bat the guy tells me I voided the warranty by opening the unit, I told him no problem cuz its out of warranty, I just wanted their thoughts on why the failure, this guy sent me to the sales department an they asked for pictures and they gave me a partial credit for a new one, if you are not comfortable opening the converter than take it to a shop and have them open it up, it might be a loose screw or who knows and when the generator is running and I guess the converter is located close to the generator the vibrations of the generator might be affecting a connection in the converter, I am a retired Operating Engineer Field Cat Mechanic, I had to learn to work on generators years ago, they had a Cat Diesel so as a mechanic I had to work on them, when Cat went electronic, I had to learn to be a computer Geek to be able to trouble shoot breakdowns, I had to add a lap top to my tool box, one of the problems that popped up on a job one time was all the electronic fault codes I was getting on several of the machines and I was pulling hair, finially got on the phone with Catapiller and explained all the problems and he asked if the machines were being parked any where near some big power lines and and I said yea they are right underneath them, we moved the parking area and all the problems went away, the EMF from the power lines was affecting the computers on the machines
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