IMPORTANT: Make sure your voltage regulator has a good solid ground. The regulator has NO solid state components which means it will work on EITHER positive or negative ground systems. If you have a six volt system you need a six volt regulator. Same with 12-volt. You briefly mention three relays inside the regulator. The CUTOUT relay disconnects the battery from the charging system with the key off. The other two relays control battery voltage and generator output current. So, when we turn the key on, how does the cutout relay energize (since the battery is disconnected)... There are resistors connected to the regulator case (usually visible from the back of the regulator). When the generator starts charging, current goes through the cutout relay coil, through the resistors, to ground which pulls the cutout relay in which also re-connects the battery. The cutout relay is the only one with normally OPEN contacts. If you have a dashboard GEN light, it will shine brightly until the cutout relay contacts close. The current relay regulates the generator field. More field voltage makes the generator outputs more. So, for troubleshooting purposes, if you temporarily jumper the BATT terminal to the FLD terminal, your generator will output at its maximum current. The voltage relay senses when the battery is up to voltage, then it 'dithers' on and off to maintain proper battery voltage. THIS is the relay to adjust for proper battery voltage. One last thought: Stay away from 8-volt batteries. Your system is designed to charge six volts. An 8-volt battery will never fully charge on a six volt system which shortens the battery life.
namaste from india I made regulator in early 90 s using Darlington cicuit using different value resistance and diodes this one is older one using relay switchi g
To lower the voltage via the Voltage Regulator thumb wheel, which way should the thumb wheel be turned? My ‘43 MB’s generator is charging my battery at 8volts at idle. I’m trying to lower that but not having much luck.
Hi Lew, thanks for this really informative video. I have a lot more confidence about fixing my jeep. It has an 8v battery in it and idles at 8.3V and puts out 8.5V when revving. Do you know what voltage I should be aiming at for the idle and recharge please? My problem is that the battery keeps running dead and I assume it is the VR not recharging.
Correct. The VR is set to charge at about 7.3 or so. Loose the 8v battery, get a 6v and check the charge output is 7.3 or 7.4v. The 8V battery is only getting a partial charge because the VR thinks there is a 6v there.
Hi Lew, I’ve had 8v batteries in the jeep for the past 14 years because Inwas told it was better than the 6v. This year the jeep stopped charging the battery and it is presently putting out around 8.5v at high revs so not enough to charge. Thats why I was going to look at the voltage regulator, clean the terminals and adjust the thumb screw on the F like you say a in the video. If that doesn’t work Incan revert to a new 6v battery but will then presumably have to adjust the voltage charge anyway to around 7.5v. Do I use emery paper such as wet n dry but dry to clean all the metal parts and then alcohol. Is there any other cleaning methods? Thanks
@@woodserjimmy got it. So the VR was tuned to 8v previously. Wet dry paper works or a small fine flat file. And cleaning with alchohol or other solvent that leaves no residue is important. Take a look at the contacts. Can you see a Peak on one side and divot on the other? Even smooth wear? Something else to check is the carbon resistors on the bottom side. They can crack and mess things up. Check for burnt insulation on the coils. Good luck and keep us posted.
Awsome, can you please help me by explaining the current reg and cut out. My mb is killing batts, my ford keeps going flat. Im hoping to use what youve shown us to figure it out. Thanks so much Lew, from New Zealand!
Basically the cutout kicks the generator on and off based on the rpm. The genny starts putting out at about 800 rpm plus or minus. The current regulator will limit the genny as it can put out a lot of current and fry things if not regulated.
I replaced battery and alternator but still alternator not charging battery disconnect battery cable car turns off checked if any power on the signal connection (the two wires) nothing no power. It must be voltage regulator a kit to by pass it?
Sir i watch your video and i truly interested because i have owner jeep 4k engine..voltage regulator with 6 wire...i have digital voltage gauge.. question my meter sometimes reach to16v then reduce to 15v..it is normal..it will not effect the battery....kindly need advice what to do..thanks
So I'm not sure if this will retain to what you're saying in your video. I have a 4 cylinder engine that was from world war II ZXB M5 GENERATOR. It has an aftermarket regulator and breaker box. So I got to figure out what wires go where. At the moment I'm just interested in trying to get the battery to charge and make the gauge work.ATM Gauge is not responding because there's no wires coming off the regulator going to a battery source. It's just a generator ran from the engine on a belt and then there's three wires coming out of the generator light yellow and green that goes to the regulator. The white wire is battery the yellow wire is armature and the green wire is FLD. I truly don't understand this even if you tell me the easiest way to do it. From the regulator do I just need to run a wire straight to the battery or get a wire from the regulator from The battery source on the regulator to the positive side of the battery cable that's on the back of the gauge panel?
Hi Lew, I need some help,.... How can I polarize my generator, seams that it is not working. (if I disconnect + from battery my engine stops) Thank you in advance for your help!
To properly polarize the generator, connect all wires from regulator to the generator. Remove FLD wire from regulator post and Flash FLD wire to BAT post on regulator and then reconnect FLD wire to regulator post.
Hi Lewis, I have watched the video with great interest and I am having a problem . I am doing a full restoration on my jeep. I am putting a temporary wiring harness together just to get the jeep fired up . I have followed the wiring diagram but when I crank the starter over the ammeter shows a positive charge and if I swop the wires over on the back of the ammeter it stills dose the same thing. I would have thought it should show a negative. I think I must be doing something wrong if you could help it would be very much appreciated Best wishes mark
I got a g506 Chevy I'm about ready to switch it to 12v, I had the generator and regulator back to the shop twice, they said they are fine but still won't charge, I ohm check the wires from generator to regulator test good and it's got power to regulator, could it be a bad gage, I'm at my wit's end
A basic test is to fire the truck up, set the throttle at 800+ rpm. Then pull the positive cable from the battery. Does the motor die? If yes, we have an issue. The test shop would have had to polarized the genny so that step should be done. Let us know what happens with this basic test.
Ok, be patient. It is almost always something simple and cheap. With the lid off the VR, running at 1000 rpm, check the cut out regulator. Are the points closed? If not, set up your meter across the battery and close the points for a moment. Did the volt meter jump from 6v to 7.4v or so?
@@MrJeep75 when you say you loosened the belt? Fan belt? Not sure what you are trying. Here is how to polarize: Reconnect the wiring and battery cable. For an externally grounded field like on a Willys, momentarily connect a jumper between the BAT and ARM terminals on the regulator, resulting in a spark. Don't clip the jumper in place, as an instant is all it takes. Battery power is present at the BAT terminal, and a surge of current will travel through the field coils via the common connection at the ARM terminal. With externally grounded field coils, the ground path is through the voltage regulator's internal contacts.
I'm sorry, but I just can't listen to you with the music in the background. What in the hell made you think that was a good idea? No upvote. No subscription. Turn the music off and make your presentation.
