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I had to do the same fix to a DCS a couple of years ago. The window was horribly discolored and bubbled making viewing of the screen quite difficult. Now it's crystal clear.

Correct. The issue is if someone re-wires the gen head leads on a 1050 and up from 208 3 PH to 120/240 Single Phase it may need some mods to also keep the DCS happy.

Might have to fool the DCS by connecting its AC sense lines the right way to keep the stock DCS happy and the VR working correctly.

The VR is part of the DCS and not a separate item in the generator.

1N5406 600 volt 3 amp

Also the second attachment in the following link may be of some help. Annotated DC schematic

Here ---> MEP-803A TMs From the TM Section of this forum

Have you downloaded the -24 TM and checked the schematics. All the wiring info is there from S1 to the Fuel Pump.

I have the mistakes that I've identified on the 802,803 wiring noted on some marked up schematic PDF's. I recall finding an error in the 831 schematics a few years back. I didn't write it down, but I could probably find it again.

Correct "Not" Sorry for the typo

Yes, and the flashing circuit. If those tests pass the VR is getting everything it needs to operate but it has failed if there is low/no AC output. If one of those tests fail, then that related circuit is likely not allowing the VR to operate properly. edit: corrected now to not in last sentence.

Step h is not a VR test. The step verifies that the generator is properly flashing the gen head and that the static exciter has continuity from the VR to the static exciter. If this test fails, the issue is NOT the VR. It's a problem with the flashing circuit, wiring to the static exciter or...

Correct pair of procedures. The 01-21501-1 is the Libby VR The 01-21501-2 is the TRC VR

Does the Voltmeter and freq meter show good voltage and frequency while you have S1 in START and the engine running? If so use the AC VR test procedure called out in the -24 TM. Use the correct procedure since your generator may have a Libby or a TRC VR. Different procedures for the two of them.

The blue box is probably the Governor Controller. The VR is the rightmost box on the back wall. If it black it's a Technology Research Corp (TRC) VR. The other VR possibility is a Libby. It's dark green.

Looks like the AC Voltage Regulator may have died. Quite common. Grab the -24 TM and run thru the appropriate VR tests and report back you findings for each step. There were two different VRs and associated parts used in the sets. Be sure to use the correct test procedure.

If you get the Generac or Honeywell make sure the 3 small fuses in the bottom of the black control box are good. Had a customer pick up an ATS and it had bad fuses.

That Honeywell is a rebranded Generac. You can see Generac on the black module on the left.

The 831 SLC100 Governor Controllers (GC) are extremely failure prone. That's why I make and sell a reliable replacement. When you move S1 from STOP to RUN the GC is supposed to put out a brief pulse of power to the actuator to pop it off the magnet. Very likely it's the GC that failed...

This... They usually nest and chew wires in the AC compartment where the K2 Starter relay is.