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For AC voltage to get to the lugs you need to close the AC Circuit Interrupter (contactor). I don't see the AC Circuit Interrupter lamp on, so it appears the contactor is still open. Lack of voltage to the outlet may be due to the GFCI being tripped or the circuit breaker on the side of the GFCI...

The fuse is a KTK-3 fuse. 3 amp Fast Acting Fuse. If the fuse is blown it's generally not a good sign. That fuse is there to protect the gen heads Static Exciter should the AC Voltage Regulator put out way too much voltage to it. Without that fuse the AC Voltage Regulator has no control on the...

If you haven't already downloaded the Maintenance and Repair TM 9-6115-643-24 from the TM download section of this forum do that for starters. From your video it appears there is an issue with the AC Voltage Regulation system. When you started the set and had S1 in the START position after it...

DS6 is getting +24 volt power from the Fuel Gauge terminal M5-I whenever S1 is in RUN so K1-1 is fed +24 volts as well as DS6-1. The tricky bit is the following... The contactor closes when S5 is lifted to CLOSE the contactor. When the contactor closes it also closes some auxiliary contacts in...

Empty 240 ohms Full 33 ohms

How's about this? McMaster Carr They have many sizes and types available. Ones I ordered last year for something. They are the PN in pic above.

From what I can see in FedLog, the Frequency meter is a current meter rated 200 uA (microamps) full scale. Since it reads 55 to 65 Hz at 60 Hz the current thru the meter should be 100 uA (microamps).

The fuse mod protects the gen head from being damaged if the VR shorts out. The Varistor (MOV) helps protect the VR from shorting out. So... it would probably be OK to load test it with just the Fuse Mod. Just a slight risk of the VR shorting out without the varistor before it's installed.

If you go to PartTarget and put the NSN 2920-00-897-2459 in the search bar you will get.. if you scroll down the page

I use a pair of 12 V AGM motorcycle size batteries in series in my 831's. They are same size when strapped together as the original 24 volt AGM battery.

The fuel level gauge operation has nothing to do with the primary fuel pump running. The -13&P schematic does show the batteries, starter motor and everything else. The primary fuel pump is to the right of the engine. The Aux fuel pump is behind the engine. I'd suggest putting S1 in the Run...

Being a holiday weekend the package won't go out until Tuesday when the post office opens. I'll ship it Priority for you.

The MOV (varistor) I provide in my kits is a 14D151K

That picture is of the circuit board inside the VR. Circled items are the diodes that can short out damaging the Quad winding and wrecking the gen head.

I'd wait until the Fuse Mod is installed. Not worth the risk of burning up your gen head. I wouldn't run it until then.

Yes it's needed. Without it you risk burning out the stator in the gen head. It's to protect the gen head if the VR fails and shorts out. A design flaw in the factory VR.

My guess it's an 831A. If so... The leftmost relay K12 is the Fault relay. When you move S1 to Run the LED in K12 will be on. Once started it should be off (no faults). K12 has nothing to do with the primary fuel pump. The pump should run when you have S1 in Run. Download the TM from the TM...

Sending PM

The tubes do not come apart despite what the TM seems to show. It's just the TM's way to illustrate the float tube passes through the round gasket.

1) Verify the two fuses on the VR are both good to be sure the Input and Output fuses are OK. 2) Start the generator and verify you get about 120 volts AC at the outlet with S1 is in START. This verifies if your set is Flashing AND it's generating the expected voltage. 3) Start the generator...