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That's what I thought you would find. Open it up. Might be able to fix it. The contacters often fill up with moisture. Then they rust up. Its worth a try, I have fixed many of them.
By "bypassing" the contactor, do you mean you jumped the close circuit? Or simply moved the cables from the input side to the output side? The contactor in the 005, is the same as the 004's contactor. I always found it simpler to remove the contactor, then test it on the work bench. It's not all...
24 volts DC is the normal working voltage. How did you check the coil? 35 volts is rather high. How did you check that at the coil? When you apply voltage to the contactor, do you hear/feel the contactor close. Not that, that is a 100% sign that it works. But it at least means the plunger is free.
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