Hey Howdy Folks,
I drove down to Memphis the other day in My 91 2500 LE.
It runs adrives GREAT
Stopped to show it off to some friends and one pointed out that the battery was smoking from the vent caps
WE put another voltage regulator on (2nd in a month with less than 500 miles being put on)
I did notice the volternator gage was running a bit high when I was driving down yonder way.

The alternator was removed a couple of weeks ago and it checked out fine.
A friend who is a master wrench checked the truck out a couple of weeks ago and we installed the 1st regulator,
Test lights were lit and meters metered, it all showed good
FAst forward ato a few days ago and regulator #2 is installed

Weird thing, I was driving it around a couple of nights before the trip and upon flicking the high ~ low beam stalk the High beams did not come on and the lights quit lighting!

Anybody out there in webville got a line on was up?

yo, just hunting the fourm and found your prob.. had the ditto problem this fall except caught it before it smoked the reg. the light switch hung up on my battle wagon and noticed the volt meter dived to the floor. got the truck home pulled the switch right quickly and it was cherry hot. metered the battery and it was indeed in the dungon. plus hot to the touch. let things cool down (and myself as well). got a new switch charged the battery check water levels in each cell( some did cook off). tested system and rolled on down the highway. Aparently the switch gave out in just the spot of the connection (or in the dimmer reostat to really load up my battery. I caught mine with in 15 miles of home so I got it with the quickness.

Hope this helps out some.

Later dude.

Turbodieselram

sounds like you need to install the heavy duty relays

big bad diesel 416's Sig:

TRUE PERFORMANCE DIESEL
SHOP TRUCK.....1990 Cummins,D250, non I/C, 5 speed 60mm turbo upgrade, 97 ported/polished head, arp studs, 50 over head gasket, rebuilt trany , 4in exaust, pyro, boost, fule pres, and cyl head temp gauges, 500,000 miles just rebuilt used most original parts Got some injectors thanks to SMOKEM 433 RWP 986TQ
WE WILL BE UP AND RUNNING NEXT WEEK trueperformancediesel.com Brice@trueperformancediesel.com

I'm with turbodieselram, change your switch.

I have had 2 regulators go bad and cooked the battery once.
It took 3 new regulators just to find a working unit the second time around.

Are you saying that the light switch caused the regulator to die?

Hey Howdy Guy's,
I'm not sure what's goin on with it. The High low beam switch on the ol sterrin colum started acting funny. I'd switch to the high side and the lights would go out on high beam compleatly. I drove it about 150 miles to Memphis and noticed the volt meter was on the high side but not pegged out. I was showing the motor to some friends and one noticed the battery smokin. We replaced the regulator (#2) and headed back. One the headlights (right side) is burnt out. Every thing else seems to be working just fine. I've not driven it in a week though. I've been drivin the 03 shorty with the v-6 (nice truck by the way) I hate to leave it sittin it looks as good as it runs and it flatt runs great I'll try the light switch thing first then go for the turn single thingy 2nd.
Perculate the info Guys!
Slimster


[/B]

looks like an alternator change is in my future sooner than later.
Started up the other morning and smelled hot wiring, touched the alt housing and it was hot.

Did some searching and found this:

136A Alternator for 5.9L Dodge Cummins Diesel

direct bolt in and with a single wire conversion to eliminate the voltage regulator.
Have a higher amperage version too.

will let you know how it works out

Just had a similar issue with mine, changed the regulator and ended up going through 3 of them to get one that worked. Now I'm back to one that seems to charge properly, but when the RPMs are up, it seems to make the needle bounce off the top end as it regulates, not sure if that's just all the better the thing can regulate is by it going up and down that much or if something is weird with the gauge. But at least mine is charging on it's own again.

92W250's Sig:

'92 W250 ExCab LongBox/518/PODs/rebuilt and tuned VE/6" Skyjacker softride lift/pyro, boost, tranny temp/Magtec double deep tranny pan

On the way - tires and rims to go with lift, more tweaks to the pump, 366 spring, Goerend convertor, smaller exhaust housing on turbo, new exhaust

Thanks for the heads up!
I'll call my parts pusher in Memphis and see what he can do about the price (wholesale ya know)
I'll let yall know what shakes out!