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What range of increased fuel efficiency in charging can be expected using such a DC generator, as opposed to DC to AC to DC charging?

Are you able to pull out those fuses and see if any are burned out?

It might be worth a try at around $20! I ordered from DigiKey. Looks like they even have a Japan version of their website. https://www.digikey.com/en/products/detail/hammond-manufacturing/162E10/455650 https://www.digikey.jp/ja/products/detail/hammond-manufacturing/162E10/455650

PROBLEM SOLVED! The correct spec replacement transformer arrived. I had to go with Hammond Manufacturing 162E10 (the previous mis-order was based on taking the recommended P/N by an employee from OEM transformer company. Lesson: check and double check specs yourself). Hammond 162E10 installed...

It does not. Resistance is very high on primary coil between pins 1 and 2.

Interesting though that the inverter/charger at least now recognizes an AC input. Previously it did not in any way.

Possibly I bought the wrong transformer... silly silly...

Well, my replacement transformer arrived. I decided to swap it out and see what happens (note that I could not get the exact replacement from MCI, but had this common-spec transformer recommended by MCI). Problem solved? Not exactly. I'm not sure if this is progress or not. The unit now at...

I have voltage coming in on both L1 and L2. Good point! I seem to be getting voltage transferring across the male/female ends of the spade connectors.

I'm able to sense voltage on the primary side of the transformer, but I can't get a voltage reading off of the secondary side. The #2 transformer has no voltage at any terminal. All spade connectors are snug. The relay has voltage from each leg of the generator AC, and has 30V output (?) on...

haha yeah, I think you can get in over your head quickly! There is definitely the potential to do more harm than good poking around. Does anything seem damaged inside your unit? I was having a hard time removing the transformer (with the tools/skills I have, 8 pins), and so I decided to order...

That's likely a good point. I should clarify/change my above statement. I have some connectivity, just very high resistance, which would generate heat. But, I barely know what I am doing...

Okay, so I think I've found the fault. No continuity between pins #1 and #2 on the primary winding. This is the transformer that was showing heat with the IR cam Continuity/resistance appears normal on the transformer located directly adjacent. It's seeming like the same issue you had...

I will try to do these tests tomorrow. I did some probing for resistance, but will try again. Do I have to remove the transformer from the board to reliably test winding resistances? It does not energize the relay, the relay is silent, the charging light never comes on, which Magnum techs tells...

Okay, so the transformer at the top of the board (4-02-3010) is much warmer than the same type of transformer directly below it. 42C

I do - I'm assuming I should do this with AC being fed into the board from external source?

But, possibly I am looking at the wrong components.

Two more images, with a slightly better top-down view of the board; and a view of the underside:

I've got my unit opened up right now. I think the voltage sense transformers we are talking about can be found under "4-02-3010" https://www.sourcengine.com/download-datasheet/4-02-3012-1476814468 Externally, I cannot see any damage. I don't know how to test them.

I can survive the winter without charging batteries from the generator, but my electric needs rise heavily as the weather warms up -- too many freezers full of incoming and outgoing farm products! My current options as I see it are: -buy a new AC board. $500-600 and hope this solves the issue...

Hello, I'm wondering if you have an update on your charging issue? Did you send the unit in for repair, if so, did you hear back on what the issue was? I've been dealing with what sounds like the exact same problem - I have the same symptoms anyways. My MS4448PAE inverter/charger has been...