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Glad you got it straight!, sorry again for the earlier misguidance. The 100/200 use the 5A wire to excite the alternator and sense wire, the 568 wire cannot supply enough current to excite the 100/200A alternators and is capped off with a blind plug and tied back to the harness.

Well it is pretty straight forward, wire #1 on the first terminal, wire #2 on the second terminal and I can only assume wire #4 on the forth terminal but without some work it is unreadable. YEP! it was time to change that 60A out for a 200A which is what I did, the 60A has been and will...

I just pulled the reg. from my 60A it has three wires, will post some pics and try to get the wire labels as it is pretty charred.

The TM shows 4 wires, there is no instructions on what wire goes where so I would assume they are marked. There may be a more comprehensive TM....

So to sum up, 24V on 5A, the large stud and 24V in the pigtail, 568 and no charging would mean a defective alt/reg.

Sorry, I am ass backwards, standby, it has been a long time since I messed with a 60A. I THINK I am up to speed. the 8GA wire 5A goes to the large stud, this is battery on the 60 but is sense on the 100/200A, 5A on the 60A like the sense wire, 568 is switched by the EESS and not hot all the time...

EDIT, see below

Yes

Also make sure 5A and 2a are not swapped, 2A goes on the smallest stud, 5A should go to the stud marked sense

Also what do you mean "measured at the voltage regulator" you should be measuring the voltage at the large terminal stud. The system is very simple, alternator grounded (bolted to engine) exciter voltage on 5A and measuring the output at the large stud. Check the voltage at the stud before...

If he has brushes it is a 60A, not sure you can turn down a working 60A to 24V, I would think 26 or so would be the lowest it would go.

Have you made sure you have the alternator excited? Wire 5A If you have alternator output it will be higher at the output wire than 24v, mid 28s is what you are looking for. Check and make sure you have 24V at 5A, basically that and a connection to the batteries on the large wire is all you need.