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>> When I disconnect DF and D+ I get a reading of 1V when I connect VOM red >> lead to D+ and black lead to gnd. > > This is normal. (The reading is positive, +1V, isn't it?) Yes > >> Then, with VOM still connected, when I ground df I get a voltage DROP to >> almost 0. I checked this three times to be sure and this is the case. > > Did you try pushing in on each brush while doing this? > Yes >> Measuring across DF to D+ posts on the generator, I show 3 ohms. > > When you install the generators, are you making sure the ventilation hole is > pointing straight down? There's a scribed line on the top that should be > aligned with the dot in the middle of the mounting strap. Is there any chance > that they gave you a non-type 3 housing that didn't even have a cooling hole? No it's a type 3 housing and it does have a cooling hole and I have always been very conscious of the correct alignment of the generator: dot aligned with line. And there is a corresponding cooling hole on the underside. > I'm just trying to imagine what's causing all of these problems. When you > attach the D+ and DF wires are they the ONLY wires attached to those 2 posts? Yes absolutely. > > If you wanted to send me the generator I would be happy to look at it, but I > realize that's not much help from this far away. You might just be better off > exercising your Bosch warrantee, or has it expired? > > If you like, I could send you a good generator first. Well, the only problem there is I worry the redundancy of the problem is caused by something wrong that's eluding me, and that it will take it out on your good generator. If that's a risk you're willing to take, then I'm game. I'm just going to be stymied if this turns out coincidentally to be the 4th generator of poor quality I got from Bosch, of all places. It's unfathomable, although the last two WERE carelessly wired... > So, the gen light stays on at idle, but goes out once you're under way? > Yes definitely > You mean that the gen light stays on no matter how long you keep the revs up > while standing still? > Yup. > VERY strange. I'm wondering if you have multiple problems: one consisting of a > chafed wire between the gen and the VR, and the other consisting of an > overheated field coil due to the occasional short to ground of the DF wire. > > Just a guess, but see what you can inspect where the wire runs. This is the problem. There's about 8" on either side (gen side or VR side) to inspect the wires. And from what I can see, they look good. The connectors are on tight, the insulation is unworn. Not even brittle. And then it goes inside a harness with a whole bunch of other wires, out of reach and out of side without destroying the harness. -M ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org