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Vibrations are great for intermittent problems.

Ray is right. When you narrow down what can, maybe, could be, is remotely possible for the problem, then sooner or later you get to the "problem area".

Let me remind you here. The MT4. Even with everything turned off, its hot. I know it sounds stupid, but lots of folks forget that. So when inspecting it, remove the neg battery terminal, or, be REAL careful. I still own several tools that have large places that have been melted out of them due...

So who out there has a like set, and will go out and take the same measurements? We have seen a few times, problems where the alternator lets AC into the DC system. For all I know, the small AC voltages you found my be normal? Dont think so, but someone should at least check. But when we had the...

How long are you running the set before taking the volt measurements? If the set has been running more then a few minutes, the DC voltage should come down from a high of 28 volts. Could be the alternator, but how about taking a reading after a half hour?