With as much work as you've done and as many questions as you've had come up, absolutely you should invest in a manual for it. In the meantime two other thoughts come to mind. First is your hot engine curb idle speed. Is it set correctly? Again, the spec engine speed would be easily referenced in the manual. If the engine is running too slow at idle, that could be part of this issue. Next, if you could identify your type of alternator, which I would expect to be some flavor of delco externally regulated, and hit google hard for the steps on how to set your low rpm cutout or whatever the hell its called. I don't even know. Sometimes if you know the make and model of the components involved, and if they were used on other vehicles, you can hit the webs hard outside of this forum and maybe find your answer. Just a thought.