Sometimes the manual doesn't have all the answers

[Summerpaws]

If the contacts close putting the two resistors in parallel the resistance should be 3.75 ohms.

Got it. I was going to remove the wires and test individually,

 

[Summerpaws]

Good Day: If your checks of all the external things does not provide the answer, you may have to carefully drill the rivets of the K8 to open it. Then you can see if things inside are in order, or overheated in a spot. POP rivet it closed if nothing found, or find short screws.

Seeing as I have a high voltage on terminal 3, to me, it is a definite cause and effect. Correct me if I am wrong, but to suspect K8, the voltages have to be correct...correct?

 

[Summerpaws]

KloppK, question. Can I do a real time voltage reading on either side of R12 and R13 under a 5K load? (or 4K). If the resistors and the contacts are good, I should get the same reading on both, correct? If the contacts were bad, wouldn't I get a different reading on R13?

 

[kloppk]

Correct. If the AC voltages to the K8 terminal pairs is less than 5.6 volts AC and you get an overload fault then I'd say K8 is bad. Since you are seeing voltage in excess of that then the issue is with the switch contacts, wiring or R12 or R13.
Yes, you would normally see the same AC voltage across R12 and R13 when running loaded in 120/240 mode.

 

[Ray70]

I'd have another go at cleaning S8. Get the cleaner inside the switch contacts and work the switch aggressively, then spray it again!
It sounds like the last cleaning made an improvement to where you can now apply a 5K load, but can't sustain it indefinitely?

 

[Summerpaws]

Correct. If the AC voltages to the K8 terminal pairs is less than 5.6 volts AC and you get an overload fault then I'd say K8 is bad. Since you are seeing voltage in excess of that then the issue is with the switch contacts, wiring or R12 or R13.
Yes, you would normally see the same AC voltage across R12 and R13 when running loaded in 120/240 mode.

Ok. For that matter, I can take a voltage reading on either side of the contacts on K8. I've left the covers off the gen until I solve this mystery so I will see if I can spare a few minutes to test that. Thank you so much for the help!