Gene-AL said: (quoted from post at 13:44:21 04/10/09) Dan,
I've based everything I've written on your report of positive +10V at the Arm terminal with Arm wire disconnected and engine running.
If the voltage output from that Gen Arm is truly positive (with Arm wire disconnected) despite your re-polarization efforts, then there's something about that generator/VR that's different from what is expected or something has been missed.
Permanent magnetism in the Gen field poles could prevent a polarization reversal, but I don't know if that happens.
JimN is correct in saying that the cutout relay is probably not opening its contacts. What else but the Gen Arm would draw so much current, but stop after a batt disconnect and then re-connect?
JimN's suggestion to use a diode will work IF the Gen output is negative and Batt is also negative (diode cathode side connected to Gen Arm). But if the gen output IS positive and the Batt negative, the diode will never turn on to connect Gen to Batt as the coutout relay evidently does.
I'd bite that battery box 'bullet' and swap the battery to negative ground (temporarily?). At least, you'd know if you have a charging system that works (Ammeter will indicate backwards if it works, unless you swap the leads).
Troubleshooting often leads to hair loss and missteps. BTDT for more years than I'd like to say, but I still have most of my hair...
"Permanent magnetism in the Gen field poles could prevent a polarization reversal, but I don't know if that happens. "
It doesn't, if the field coils are good. You can flip these generators back & forth from pos to neg to pos output till the chickens come to roost, without a problem. Done it, many times.
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