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Contrary to popular belief, the Model A 3 brush generator develops constant current; not constant voltage. The primary control of voltage is the resistance of the entire charging circuit from the generator output, through the battery, to the frame. If you have high voltage at the cutout output terminal, above 8+ volts at 8 amps, check the voltage drop from there to the battery negative post. It should be 0.5 volts or less. If more, it is probably your wiring, so fix that.
Also check the voltage drop from your positive post to the car frame. It should be infinitesimal.
If it is not those, it is your battery resistance. You can have high battery resistance from a defective battery or an overcharged battery. Fix that and you are home free.
Now, since voltage varies directly with the charging circuit resistance, it follows that when there is a break in the charging circuit, the resistance becomes infinite and the voltage skyrockets. When that happens, the voltage breaks down the generator winding insulation and away we go.
Conversely, we are told to ground the generator output wire to the cutout if the charging circuit has broken (a scary thought). In this case, the resistance is zero therefore the voltage is zero and, without voltage, there can be no current flow. No current flow, no burned windings.
Also check the voltage drop from your positive post to the car frame. It should be infinitesimal.
If it is not those, it is your battery resistance. You can have high battery resistance from a defective battery or an overcharged battery. Fix that and you are home free.
Now, since voltage varies directly with the charging circuit resistance, it follows that when there is a break in the charging circuit, the resistance becomes infinite and the voltage skyrockets. When that happens, the voltage breaks down the generator winding insulation and away we go.
Conversely, we are told to ground the generator output wire to the cutout if the charging circuit has broken (a scary thought). In this case, the resistance is zero therefore the voltage is zero and, without voltage, there can be no current flow. No current flow, no burned windings.