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Testing of the AC Voltage Regulator is covered in the -24 Generator TM ---> TMs Be aware the generator was made with 1 of 2 different AC Voltage Regulator systems. One by Libby and one by Technology Research Corporation (TRC). Be sure to use the correct test procedure in the -24 TM.

TMs ---> Generator TMs

If blue plastic it's Kraus. Prone to failure. If round and metal it's ElectroSwitch. Just about bulletproof.

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Before tearing into K8 (it rarely goes bad) I'd suggest measuring the AC voltages going into K8 as detailed in the thread I suggested. Very likely you'll find one or more of them way to high causing K8 to trip the overload. This post.. (updated below for your trip point) I'd suggest doing the...

Check out this thread. Lots of good info on things to test to track down the cause of a false overload. False Overload Issues

You can also replace K2 with a standard 24 volt starter relay. Something like this. You may need to change the wire lugs to fit the t

Have you tested the Exciter Stator resistance to be sure it's good? TM says it should be about 12 ohms. Have you measured the DC voltage going to the Exciter Stator while the genset is flashing the gen head to verify the DCS is sending the flashing voltage? If you do see a flashing voltage to...

Have you performed the troubleshooting steps in the -24 TM for that fault? Results?

There is no need to externally "flash" the gen head. THE DCS takes care of doing that automatically. Excerpt from the -10 operators manual... Field circuit in lower left below

Housing and pins one end Molex Housing P/N 3092042 DigiKey Housing Molex pins P/N 2092103 DigiKey Male Pins Housing and Pins other end Molex Housing P/N 3091042 DigiKey Molex Housing Molex Pins P/N 2091104 DigiKey Molex Pins Pins can be soldered onto the ends of your wires and snapped...

The connection between the A9 and the float switch is done with a 4 pin Molex connector. To do the mod without cutting any wire could be done by building a little adapter like with a male and female Molex connector to tap into the FL2 circuit. Something like this...