lets get very specific.. this is an esy issue to trace that is being made difficult due to lack of clarity of posts.. way too much time is being wasted here.
1.
with genny arm hooked up.. do bat terminals spark when being disconnected?
if yes, put a test lamp inline to arm.. if it lights up guess what.. it's the load.. whatever cutout or diode setup you have is not working. if a diode.. is it installed backwards?
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