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Terminal 2 on the factory VR and my VR do not get any wires connected to them. The wires that were on the factory VR get hooked to the same terminal numbers on my VR.

Double checking.. The generator was putting out correct voltage just before T1 smoked? Now with T1 yanked no AC voltage even with S1 in Start? If so circle back and check the DC voltage across VR terminals 1 & 3 with S1 in Start

Yup

Ditto. Ignore the other TRC stuff. Not involved with AC voltage regulation. Just disconnect T1 completely. Isolate each of the leads. T1 is not needed or used with my VR. Per our conversation the other day T1 seemed to have a problem since it was dragging the 208 input down.

I tested R4 & R5 in two Libby VR's I have here. In one VR R4 & R5 both measured 2.405 K Ohms each when measured in circuit. Polarity didn't make any difference. In the other VR R4 & R5 both measured 2.415 K Ohms each when measured in circuit. Polarity didn't make any difference.

Removing the fuse or the wire from VR terminal 8 will kill power TO the VR. However doing that does not stop the flashing function and the gen head will still generate power when S1 is in START. A better way is to disconnect the P5 plug. This will disconnect power to the VR and prevent the...

Having wires 6 and 9 reversed would cause the windings in the stator to be incorrectly configured. All that current would have passed thru the contacts of S8 the phase voltage switch possibly welding some of its contacts together. It's tedious but you'll want to test S8 to verify all contacts...

An Over Voltage Fault would be the AC output. That R5 looks crispy. Will take a close look at a couple of factory VRs I have laying around.

Actually they are not potted on the inside. Someone posted a pic a few years ago of a CT opened up. Just 3 separate coils suspended by the plastic housing. ** Warning If the output of a CT doesn't have a load on it, it can generate extremely high, lethal voltage

From the -24 TM

When shuts down are any of the Fault lamps illuminated?

You can leave the batteries hooked up in series when using two 12v chargers. Yes hook each charger to each battery. The only time you can't do this is with chargers with a 3 pin ac plug and battery charger negative is connect to the ac plug ground pin. Ask me how I know :LOL:

I have about 10 various NOCO chargers I've been using for years. Just installed a pair of the new Genius2D units in my 1030. The only failure I've encountered was with a 7200 I bought years ago. NOCO replaced it with a 15000 under warranty with no hassle. Very pleased with the NOCO products.

The wiring diagram in the -24 TM shows which relay is which.

Here is a link with batteries for that NSN. Scroll down Batteries

Yes, all the same except the leftmost "relay" looking thing known as S14.

Missing Fuse for alternator and the K12 Fault relay. Contactor not closing isn't to difficult to troubleshoot.

Jeff, T1 transformer in your 804. Top view.

Check for about 24 volts DC with respect to chassis ground at S10-3 and both used terminals on the S17. All should have about 24 volts DC on them. If they do then check the two terminals on CB1 for 24 volts. If they do then check S1 terminals 2,4,6 & 8 for 24 volts. Check S2-2 for 24 volts too.

A picture or two of whats behind the gauge panel too. Is the exhaust flap in place?