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The red marks in your diagram should have continuity with S8 in position 3. Might some of the jumpers be missing from S8?

With S8 set to 120/240 B1 is floating and not connected to any windings. L2 is not used in 120/240. Only A1 & C1 are connected to the windings and of course L0.

I was also thinking it may be a wiring issue or switch issue somewhere between TB3 and K1 when suggesting to check the resistances.

Also check the resistance between A1, B1, C1 on the contactor and ground. All permutations.

You should also verify that there is no connection between each of the windings.

Be sure to check the wiring on S8.

I highly recommend NOT starting the set again until you find what is causing a huge load. You can quickly burn up the windings in the generator stator rendering it useless. Here is one that burned up about 2 months ago that exhibited the same bogging.

The genius 1s should be fine to keep the batteries topped off between uses.

Ok, 22 volts indicates a continuity problem from there to the Exciter or the Exciter itself. The power from the VR to the Exciter goes thru the P5/J5 connector. I'd suggest checking the 4 pins in those connectors for corrosion. Then check the resistance between P5 pins 1 and 2 to verify...

OK, as you move S1 from RUN to START do you see K15 moving?

I'd suggest measuring the DC voltage across A1 terminals 5 & 6 with the set running and S1 in Start to see if the set is flashing the gen head. The voltage there should be approx 7.6 volts DC. If you get around 7.6 then the flashing circuit is working. If you get around 24 volts then there is...

Yes, It has to be removed to do the testing as I showed above.

I posted the schematic of the A5 card a couple of posts back. Here it is again.. Here is the test setup and test procedure for A5

Proper voltage with S1 in START is a good sign. To see if the Quad winding is putting the proper voltage measure the AC voltage across A1 terminals 7 & 8 when S1 is in START while it's running. YOu should get approx 69 volts AC there. If so the Quad windings are working. Also measure across...

edit... OK then you ought to do the Voltage Regulator testing listed in the -24 TM.

114 is close enough. Just needed to see if the set was able to "flash" or not.

That's the correct fuse. Do you get ~120 volts AC at the convenience outlet when you have S1 in the START position while running?

R3 is a 1,500 ohm resistor. It provides power to the diode bridge CR4 which in turn provides DC power to the K7 relay coil causing K7 to close.

PM inbound

I've been looking around to see if I can acquire or get access to an 002/003 for such an undertaking. No luck yet.