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On 23 May 2002, at 9:27, Martinez, Leon wrote: > I hooked the ammeter between the big red red wire and D+ on the generator > and I found the following: Okay, just a temp connection to make checks? Very reasonable. > - After starting just after 1/2 hour of radio time parked 30 + AMPS then > within seconds drops to 13 amps. Sounds pretty normal. > - Removing my electric fan wire (1 big fan and 5 little ones, running for 9 > months now) 6 AMPS being drawn with EFI and coil only operating, including the Gen > field. So the fans use more power than the EFI and ignition combined. Interesting, but probably predictable. > - Everything on (High beams, fog lights, stereo, emergency blinkers, wipers > etc..) 22 AMPS Sounds right. (Oh that poor underpowered 30A generator! ;-) > All of this looks like normal load and the battery is still getting 13.5v - > 13.8v from the regulator and with no load 14.3v to 14.6v . No RPM change with > the Gen disconnected. I assume all of these measurements were taken while driving or at medium RPM, otherwise I wouldn't expect you to get much out of the generator. The loaded voltage is a bit low, but this is probably due to the voltage drop in the extra ammeter wiring. This is why you either need to use really big wire, or just to a temp install. > It all seems that when the brushes wear out they would arc to the commutator and > leave sharp spots in the copper thus wearing the new brushes out. I gues I > should not just throw brushes in but should either replace them before the light > blinks or lightly sand the comutator before putting new ones in, I assume this > can still be done without removing the Generator from the engine. I strongly recommend that you NOT sand the commutator for the reason I gave earlier. Getting it turned is probably a good idea. They may also discover that one of the bearings is getting bad, and I suppose it is possible that the vibration from a rough bearing could cause the brush not to ride smoothly, thus causing it to wear out. That's theory only; I've never seen it happen. BTW, it's EASY to spot a noisy gen bearing with a long screwdriver, one end stuck on one end of the generator and the other end in your ear. Compare the two ends, you may be amased. - ******************************* Jim Adney, jadney@vwtype3.org Madison, Wisconsin, USA ******************************* ------------------------------------------------------------------- List info at http://www.vwtype3.org/list or mailto:help@vwtype3.org