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Your readings for R12 & R13 indicate a probable contact problem in S8. With S8 set to 120/240 R13 gets hooked in parallel to R12. So when checking the resistance across R12 & R13 you should get virtually the same resistance. Since you aren't and R13 is reading 7.6 ohms this would cause K8 to...

Correct two terminals but B1 is B2 and B2 is B1.

I'll do the same resistance checks on my set with S6 & S8 in the same settings and post up what I measure tomorrow.

Can you re-do the current measurement and measure the AC voltage across R11? With 0.19 amps AC thru R11 the voltage across the terminals should be 1.42 volts AC. Here is a diagram of the %Load circuit in 120/240 mode and AMVM set to the 3 o'clock position.

1 A is 133% Load 0.752 A is 100% Load You need to hook your meter in series with the sets %Load meter. At 100% Load the burden resistors should have 5.6 volts AC across each of them. At 133% Load the burden resistors should have 7.5 volts AC across each of them.

The %Load meter is NOT a voltmeter, it's an ammeter. 1 amp Full Scale. That's why you see very little AC voltage across the terminals.

A great tool for finding electronic parts is Octopart.com Just put in the part number and it will display what distributors carry the part, how many they have in stock and pricing.

Newark has 4 of the 08490

Before your post I tore the roof off my 802 to check if 7 to 8 was closed in 120/240. It is... Time to put my roof back on now that the mystery is solved.

Since you can see the contacts set the switch so 8 is "closed" and then look into cavity by 7 and see if it appears "closed". If so I'd then check continuity from 7 to 8. If no continuity, then I'd run a point file or something between the contacts and then recheck continuity.

Here are some pictures of the innards of some of the many layers of S8. Pictures sent to me by someone who tore one apart. And yes they can fail...

I suspect you may be checking the wrong terminals on S8. For checking for continuity between 7 & 8 you need to probe these spots.

The red marks in your diagram should have continuity with S8 in position 3. Might some of the jumpers be missing from S8?

With S8 set to 120/240 B1 is floating and not connected to any windings. L2 is not used in 120/240. Only A1 & C1 are connected to the windings and of course L0.

I was also thinking it may be a wiring issue or switch issue somewhere between TB3 and K1 when suggesting to check the resistances.

Also check the resistance between A1, B1, C1 on the contactor and ground. All permutations.

You should also verify that there is no connection between each of the windings.

Be sure to check the wiring on S8.

I highly recommend NOT starting the set again until you find what is causing a huge load. You can quickly burn up the windings in the generator stator rendering it useless. Here is one that burned up about 2 months ago that exhibited the same bogging.

The genius 1s should be fine to keep the batteries topped off between uses.