In Reply to: Re: 2N charging system (again!) posted by Steve Frysinger on October 09, 2017 at 20:44:43:
You are trying to diagnose and correct an electrical problem by beginning in the middle and working toward each end and returning to the middle.
Begin with the battery. just because "it holds a charge" does not mean it is good. THe only ways to properly test a battery is to load test it. That does not mean testing with a cheap AutoZone tester, You have to apply a load in excess of 200 amps for at least five seconds. If it holds, slow charge it until it is completely charged and check with an hydrometer. Your battery is very likely bad.
There are other tests that can be performed, cell voltage drop test, cell voltage drop test under load etc. Nine times out of ten a properly done load test will ID the problem.
A battery that has been run down, sometimes left for along period possibly during a cold snap and probably fast charged many times is very likely to have sulphated plates. That battery is bad.
Are the cables good? Are they bulged at the terminal ends? Is the ground strap mounted bright metal to bright metal?
WIthout knowing for sure if the cut out is internally grounded or not I would make sure it is properly grounded.
Motor test the generator. If it fails that test take it to a shop and have it tested. You could check the fields and commutator with a continuity tester but you need a growler to test the armature.
If the generator is good, the battery is new, the wiring is good, and there is still a charging problem the cut out is bad. Period. You don't have a new cutout. You have a year or two old cutout which may have been run with a generator with a shorted field or armature and likely subjected to external charging amperages in excess of its rated capacity.
Did you disconnect the battery every time you recharged the battery?
Hope this helps. Electrical can be frustrating but problems can be solved using an orderly system of testing.