Dan, a couple things you say have me a lil worried......
"I tried to full field the gennie to no success"
When you say "full field" what are you doing exactly???? To see if its a genny or a VR problem you DEAD GROUND THE GENNYS FLD POST. If it charges then but NOT otherwise its EITHER a bad or misadjusted VR ORRRRRRR the VR isnt well grounded ORRRRRRRR the wires bad from FLD on VR to gennys FLD post. INSURE BOTH THE GENNY AND VR HAVE GOOD GROUNDS
"the gennie will motor fine and pick up speed when I remove the ground at the arm post while testing"
To do the motor test you first ground the gennys FLD post,,,,,then you apply hot batetry voltage (like from BAT on the VR) to the gennys ARM post n she ought to spin, then you remove the FLD off of ground n it should speed up. If it passes BOTH those tests it ought to charge.
Try the dead ground of the gennys FLD n see if that makes her charge (if so I suspect a VR problem or its not well grounded) ,,,,,,,Insure the VR and Genny BOTH are well grounded,,,,,,
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