Patient: '49 F1 Stock I6 226
Symptoms:
Year old battery doesn't hold a charge with use
Gauge shows no charge - with headlights on shows discharge
When charged, truck had fired right up - until the last few weeks.
Now had cranked but wouldn't fire - once started, would run rough.
When battery was low, could push start without issue - or use a portable booster battery pack. When started off the pack, engine would run great until the pack was disconnected when it again might drop to a rough idle or simply stall.
Today, on the ride home from my brother's place, it stalled out several times - wouldn't rev after starting without a fight and barely made it the 5 miles back home.

Got it in the garage and started to remove the cover on the voltage regulator. As I was disconnecting the ground screw - it sparked several times and before the cover was removed, the cutout relay on the battery terminal fried (the resistance coil glowed and broke).

Now, I'm sure that disconnecting the battery BEFORE I started on the regulator would have been smarter. I'm wondering if this didn't help clarify the situation.

My diagnosis: The voltage regulator has been in a death spiral and replacing it will solve my battery charge, starting, and idle issues.

What say you, members of greater wisdom? Am I anywhere near correct? Rep points hang in the balance....

DW

 

FortyNiner it is still generator? If so I'd do as you suggested and change regulator but I'd also maybe change brushes in generator and then reconfirm regulator is grounded. Just my 2cent.

 

I think you are on the right trail. The low voltage will be insufficient to fire the coil proper

 

It is a generator set up, Kurt. Changed the brushes several months ago.

DW

 

Well then it does seem like you are on the right track. Good luck.

 

Was one screw off the cover, and the cover pivoted on it, when the resistor got hot? The cover can short the cut-out relay to ground if it gets sideways. I guess you'll find out if that was the problem when you replace it. I can't see that it really says anything about the condition of the reg beforehand, tho.

 

Fair point, Ross. The painted regulator cover shows a contact point above the cutout where is likely shorted.

So, if the regulator wasn't the culprit, any idea on other causes?

DW

 

There are cases of battery failure caused from within the battery itself. Things like plate mechanical separation, shorting of a cell and more. It does sound like that battery may have seen better days.
How do the points look on the now-dead regulator?

 

Most of the bling stores have a battery tester that checks the condition of the battery function for free

 

Jeremy - the points look good and the battery is less than two years old.

As I looked at the cover on the voltage regulator got to wondering: Should the inside of the regulator cover be painted? This one is and not a factory finish. Any impact?

 

Maybe a bad battery and a weak coil. Running rough may have been because the coil wasn't producing enough juice to fire properly.

 

Good point - may need to eliminate all the variables in the chain.

 

Charge it before you test it.
As for paint in lid, shouldn't hurt as long as a good path to ground is maintained for the regulator to function.

 

1. Load test and charge the battery.
2. Make sure all cables are heavy enough to carry the amperage required of six volts and that the ends of the cable are not compromised with corrosion. That is a pretty long stretch from the battery, around the rear of the engine to the starter and requires a big cable.
3. Check to see if the generator will "motor". If so, replace the voltage regulator and make sure the generator belt is not slipping.
4.End of problem.

 

Make sure all you grounds are attached and tight.