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As I recall the exciter winding draws 1 amp or less from no load to full load. If the VR is putting out say 2 amps of current into the exciter I could see it overvolting and not blowing the 3 amp fuse.
I produce a replacement A1 VR for the 804B. Should after your testing and troubleshooting determine the VR you bought is NG I have them available for shipment.
TM 9-6115-643-24 is the Support & Maintenance TM. It has troubleshooting procedures for most aspects of the genset.
It's available for downloading in the "TM" section of this forum.
Does the set have the correct T1, R16 & Voltage adjust potentiometer to work with the TRC VR you put in?
A set with a Libby VR uses different T1, R16 & Voltage adjust potentiometer.
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