Re: repeditive generator failure

Posted by Owen_Dyneto On 2011/10/31 12:09:16

Certainly O or OO gauge cables are important for good 6-volt performance and they should be replaced if yours aren't up to snuff. Clean connections expecially the ground on the battery cable is important as well. But cable size is extremely unlikely to be the cause of your problem. Your starter can draw upwards of 500 amps and hence the larger cable, the generator output is around 25 amps, just look at the size of wire from the armature to the BAT terminal, very much smaller - even an extremely undersize wire can carry that load as long as you don't have to start the engine again.

You did say you polarized the generator. Did you happen to put a voltmeter across the battery as a simple test of the charging circuit? With the engine idling, battery voltage should be about 6.6, give or take. Rev up the engine with a load on like headlights or heater, and it should rise to perhaps 7.4, give or take. Also of course the headlights should get noticeable brighter.

With a fully charged battery, driving 150 to 200 miles of daylight driving with no charging circuit is entirely possible - I've known many folks who have done that. Perhaps you've never had a functional charging circuit?