"I guess I could use some feedback as to where to go from here.
As mentioned earlier, offset is clearly a problem especially in the right channel which reads at -348mV. Would this have kicked in protection that disengaged the output relay? Am I saying that right? "
Could be. Either way it should be solved before moving on. Protection circuit looks at the speaker output and if it sees a DC value over a certain nonadjustable value it disenges the relay to keep from frying the speakers. .348 is high and indication of a problem. A troubleshooting assumtion that I have always used is I assume that the unit had worked at one time and that there is only one problem with it presently. This tends to keep me from chasing too many bunnies into the tall weeds (keeps me on track) and most of the time it is correct. Now with new homebuilt stuff all bets are off as many many errors are often present.
"I am still curious as to why sound never cut when I had 8 ohm speakers hooked up but did on the first day a tried the 4 Ohm fellas."
Mysteries of life. One learns to just continue the troublshooting hunt until it is solved. All will to clear in the end or won't matter anyway."
"I do have the schematics on this unit but not the service manual. Suggestions on where I might locate one. Preferably for quick download."
I wait patently and find bargin manuals on E-bay. Others will have to help you with this. Not many offer download copies if any.
You might be able to locate the DC balance adjustment on the schematic but the service manual will make it much easier. I recommend buying a service manual on anything you plan on keeping for awhile. Even if you elect to have a pro work on it they most likely won't have a manual and will have to order one and charge you plus mark-up. If you sell later, having the manual is an added selling feature.
"I should also mention the unit has appearantly never been opened and looks really dusty inside. Best cleaning suggestions?"
I use a shop vac set to blow and use a soft brush to help move all the crap out. Don't get too close with the air blast, start with a couple of feet away. Anyway works fast. Later if you want shiny clean then a small WD-40 soaked brush and rags works for me.
"I'm assuming I should avoid hooking this thing up to speakers (at least ones I care about) until I get this resolved. "
That is correct, the high DC unbalance on the left channel is an indication of something wrong and until it is solved you are relying on the protection circuit to keep your speakers alive and well. I picked up cheap thrift store speakers to use when checking out unknown gear. Think of them as cheap test gear.
I really appreciate the time you guys are taking on this.
"What, like we got a life or something? "
"And finally, should I relocate this post to DIY?"
No I think you are in the correct forum. The moderator would move it if he feels like it would get better coverage in another. DIY is for building new stuff and a bunch of wierd tube and homemade cable guys tend to hang there, hehehe
You might consider starting a new thread on your next questions as this one is getting kind of lenghy.
Lefty