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I did some work for someone a couple of years ago converting a pile of new 400 Hz 804/5/6 VR's to support 60 Hz operation. It required changing out about a dozen parts to make them 60 Hz units.
I haven't gotten into fixing them for the reasons Guy mentioned. If you have a failed one I'd first...
Quad Fuse Mod circled.
It gets installed on the back wall behind the gauge panel just to the left of the A1 AC Voltage Regulator.
Fuse should be a FNQ-R-3 instead of the KTK-3 in the picture.
The reason proper AC voltage is present with S1 in START is that the set is "Flashing" the gen head to kick off generation.
Flashing is NOT done by the AC Voltage Regulator. It's done by other components behind the gauge panel.
When you release S1 back to Prime/Run the AC Voltage Regulator...
From what I could see that control box was designed to upgrade a 804B to be part of a "Micro Grid".
Basically a bunch of generators that can load share and are automatically started and stopped based on load demand on the Micro Grid.
Here is an example using AAMPS gensets
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