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Old 09-08-2010, 01:22 AM   #1
smitty1
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Default 78 Model D gasser not charging

My 78 runs like a top but for some reason is not charging the battery. Battery checks out good, generator checks good. I guess that leaves the regulator. When we did a charge test on it the meter just went nuts and wouldn't show a steady reading. Did this with the meter on the battery and with it hooked to the regulator terminals. Any ideas??
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Old 09-08-2010, 02:38 PM   #2
chaz66
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Default Re: 78 Model D gasser not charging

I had lots of problems with my '70 Model D electrical system. Funny I learned quite a bit about "vintage" electrical system design.

There are 5 terminals on your starter/generator. A1 A2 F1 F2 and DF. If any one of the connections is bad it wont charge. The good news is if it works as a starter A1 and A2 are good, and you have a good chance at repair. I would check all the connections first and "wring out" ie test continuity with a meter all the wires. Next check the continuity of F1 to F2, should have no resistance. Next try DF to either F1 or F2, again no resistance. If all this checks out good its possible it could be the regulator. The good news is its simply a Bosch ( read 60's volkswagen) regulator so you can get them cheap. You cannot test the regulator with a regular meter. Long story short the regulator isnt a real regulator its an extremely simple way of controlling the current to the field windings (DF) it is so simple that short of melting it is unlikely to fail.

If you need some more help pm me and we can chat.

My problem was a broken field winding (f1-f2) I was able to repair it fairly easily.

Chaz
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Old 09-09-2010, 01:48 AM   #3
smitty1
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Default Re: 78 Model D gasser not charging

Denny at the alternator shop did a complete check on my starter/generator and said there wasn't a thing wrong with it. I will check the terminals with a meter and see if they check out. Even though my regulator is used it is very clean and looks new. So far everything points to the regulator. Thanks Chaz for the reply. I'll let you know what I find.
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Old 09-09-2010, 10:01 AM   #4
chaz66
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Default Re: 78 Model D gasser not charging

I almost forgot, the regulator needs a ground to function properly. The ground is through its case. Is the regulator bolted tightly to the frame? No paint on the regulator mounting tabs, or frame?

Chaz
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Old 09-09-2010, 10:11 AM   #5
smitty1
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Default Re: 78 Model D gasser not charging

I put a jumper wire from the mounting tab on the regulator to the negative post on the battery.
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Old 09-09-2010, 11:06 AM   #6
tew45
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Default Re: 78 Model D gasser not charging

Your cart should use the Hitachi voltage regulator. Testing is covered on page 5-50 in the manual. Careful with the regulator for is is easily damaged by shorting the wrong place without some connections removed. It sounds like a bad regulator or wiring. Make sure all grounds are tight! You must have a good ground from engine to frame. A dedicated ground wire is needed.
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Old 09-10-2010, 01:08 AM   #7
smitty1
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Default Re: 78 Model D gasser not charging

All grounds are good. It is indeed a Hitachi unit. I did the test and what threw me was that the meter just went crazy. I could not get a steady reading for the charging voltage.
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Old 09-10-2010, 08:03 AM   #8
tew45
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Default Re: 78 Model D gasser not charging

I would bet the regulator is bad!
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Old 09-10-2010, 04:02 PM   #9
chaz66
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Default Re: 78 Model D gasser not charging

The Hitachi Gen is paired with the Hitachi reg from the factory. However both regulators are "vibrating point" and work identically. The difference is the hitachi has an internal screw to reduce the maximum point gap and subsequent current supplied to the field. Either reg will work with either gen. Erratic voltage from point type regulators is unusual. The vibration of the points is directly linked to the voltage across A1-A2 that voltage is controlled by varying the current to DF the field. The regulator would need to change its point vibration speed randomly and wildly. More likely the connection either internal to the Gen or the DF wire has some issues. Typically these regs fail when the points become stuck together or the electromagnet windings break. I suppose its possible for the internal reg connections to be intermittent. Let us know what you find!
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Old 09-14-2010, 09:26 AM   #10
smitty1
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Default Re: 78 Model D gasser not charging

I didn't get up to camp this past weekend so I didn't mess with my cart. I did clean the points on the regulator and grabbed a spare I had. I still don't think this regulator is bad. Me thinks it may be a wire issue. Hopefully I will figure it out. I will keep ya all posted. Thanks for your suggestions and info.
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