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The Hz meter won't work reliably unless the set is putting out 120 volts AC to the outlet.

4.2 is certainly shy of 5.0. Even at that the generator should be putting out somewhere near 120 volts at the convenience outlet if the VR is good. All things so far point to a bad VR. To double check, I assume you get around 120 volts AC at the convenience outlet with S1 in START, but then it...

It should have varied from around 0 to around 5,000 ohms. Was it generally in that range when rotating it from stop to stop? The meter may have read something like 4.98 K instead of 4,980 ohms for instance.

And 0 ohms resistance all the time when you disconnected wire 156A from the VR and then measure the RESISTANCE between wire 156A and terminal 2 of the VR while rotating the AC Voltage adjust knob?

OK, that would indicate a problem with either the wiring from VR terminals 1 & 2 to the voltage adjust potentiometer on the front panel or a problem with the voltage adjust potentiometer itself on the front panel. Just to re-verity. You measured 126.7 volts AC between VR terminals 3 & 4 with...

That's good. It indicates the exciter is working, flashing the gen head and the gen head stator is putting out AC voltage. That's not good. When you did the test did you disconnect wire 156A from the VR and then measure the RESISTANCE between wire 156A and terminal 2 of the VR while...

7.6 volts there is exactly correct. TM says "approximately 8 VDC". 7.6 VDC is what I measure on my good working set. Measuring 7.6 indicates the "flashing" circuit is working and you have continuity from there to the exciter and the exciter is receiving the voltage. What voltages and...

The blue device is a MOV Metal Oxide Varistor better known as a surge protector. It's there to help protect the VR from voltage spikes from the Quad Winding which can cause the VR to short out damaging the Quad winding. I have them available. PM me and I can send you one.

If you can post a picture of the readings on the gauge panel with the set running so we can see the gauges.