[rotorwrench]

Battery condition has the most affect on how the generator works since it controls the voltage in the system. A high resistance connection on the battery can over tax the generator. The one thing about a stock 3-brush generator is that it will put out a constant current all the time whether it's needed or not. The current output is adjustable with the 3rd brush. Perhaps it is set too high but a bad battery connection could also be a problem.