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The Start relay is NOT in the row of relays behind the gauge panel. These are the relays and functions of the relays in that row. The START relay K2 is located in the AC compartment which is behind the wall where the relays above are located. You need to take the roof panel off to get to...

I assume when you say "starter relay" you are referring to relay K2? If so, you'll want to see if terminal A1 on it is getting 24 volts all the time. Then check terminal A2 for 24 volts when you try and engage the starter from the Dead Crank Switch or S1. You may have multiple issue since the...

With the set running see what the DC voltage is across VR terminals 1 & 3. With the set running see what the DC voltage is across the VR wires going to M7 & K15. It ought to be about 24 volts

Yup, yours is set to 416

This one is set for 120/208

As I recall 208 and 416 is marked on the base and the plate has an arrow on it pointing to either 208 or 416. The plate gets moved up or down to change the AC output voltage. Need to remove the nuts securing the plate to reposition it.

I started suspecting it may have the wrong or defective shunt in it. Usually when they go bad, they totally open up.

Do you have the voltage reconnection plate in the 208 or 416 position?

I'd suggest just securely zip tie it out of the way on the back of the panel.

It is misleading that L3 is stenciled there at that switch position.

He needs to remove the Gear End Cover over the governor. This.. The TM calls out to insert a screwdriver through a hole in the flywheel housing to get to the ring gear (to keep the crankshaft from turning while removing bolt 5 above.) There doesn't seem to be a hole in the flywheel housing...

Actually with the set in 120/240 and the AM-VM switch in the 3 o'clock position the Load meter will show the total load of L1 and L3 combined, not just L3's load. The Load meter is measuring the current produced by the gen head windings, not what's being drawn from each lug (except in 3 phase...

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I'm right here

Here is a version of DieselAddicts DC schematic for the 803A. It's the same as the 802 except for the two additional intake air heaters the 803 has. I marked it up with the base wire numbers in blue/white and terminal & pin numbers in red/yellow. Base wire numbers indicate the wire prefix of...

The schematics are at the back of the -24 TM. @DieselAddict put together a nice PDF version of the DC schematic.

This one..

I call the 1/4" galvanized mesh "rat wire"

They are mounted on the left side of the back wall behind the gauge panel. Here is the layout of the panel they are mounted to from the -24 TM. R10 thru V5