intermittent converter problems

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When the batteries were tested were they given a full charge first? The chassis battery shouldn't have affected the converter/charger output unless you had a Trik-L-Start or equivalent connecting the batteries together.

Did you do a no load test of  the converter/charger with the batteries disconnected?

The change in voltage may just be a combination of fully charged batteries and cleaned connections. That converteer/charger output is still low.
 
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