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Baffling charging issue
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   Maintenance and Repair -> ElectricalMessage format
Posted 2016-08-22 12:18 PM (#152504)
Subject: Baffling charging issue


Posts: 17

Location: Westford, MA
This may have been covered in some previous thread, but given the details I figured I'd start a new one.

Couple of weeks ago, my alternator stator coil connector (3 white, 1 red, 1 black) shorted and melted. While I was waiting for the new connectors I ordered, I pulled the alternator - visual examination showed no signs of excess heat, burnt coils, etc. The resistance tests on the field coil and stator coils show everything in spec. Testing the rectifier / regulator showed that it was faulty, so I bought a new one from Caltric (more on that in a moment).

I rewired everything with new connectors. All the tests come back good. The resistance tests, the diode tests on the regulator / rectifier. When I turn on the ignition, there's about 12.8 volts on the brown wire for the regulator connector (1 brown, 1 green, no black), and with the engine off, about 1.8 volts on the green wire - just as it's supposed to be. With the engine running, I see about 9-11 volts on the green wire when I rev the engine - just as it's supposed to be.

The voltage coming off the stator coils with the engine revving is about 80 VAC, just like it's supposed to be.

BUT, the charging voltage to the battery won't go over about 13 VDC. If I unplug the regulator connector and short the green field coil wire wire to ground, I can see the charging voltage shoot up when I rev the engine.

So everything seems to be working properly, except with the regulator plugged in.

I saw the thread about the Caltric unit - is it really possible that the Caltric regulator is faulty or manufactured wrong such that it's holding the charging voltage to 13 VDC?

Is there something else I'm missing?
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