63 Pan Charging with too high Voltage

[63 Duo]

My 63 Has a stock 61 model generator rebuilt with new coils and rotor and brushes 3000 miles ago. Also a 3 unit DELCO REMY police NOS regulator and it is a 6 V system.
One week ago it boiled my battery and found by measuring the voltage that it went from 6.5 V at idle, to more than 9V at some 2-3000 RPM!! tried with a friend mechanic (we were on the road) to regulate it adjusting the regulator screws but it does not drop . tried at home another 3 unit regulator (not same model but 6V) and same high measurements.
Measured generator output at approx 2500 RPM (without regulator) and it goes up to 11V.
Inspected visually internals of generator, they look ok.
Any ideas?

[john HD]

sounds like the field terminal is grounded, that puts the generator at full output.

john

[63 Duo]

Thank you very much John, i wiil check that and post results,i hope that it will be that simple...

[john HD]

This may help you get your regulator back to spec. https://www.hydra-glide.net/phpBB3/view ... 101&t=6796

pay close attention to the 2 resistors in the regulator, they set the base charging level. if they are shorted you will get the same results as you are experiencing.

However, since you tried another regulator I would look at the wiring and the generator itself first.

john

[58flh]

I have found that any 3-coil reg./be it delco or some off brand There good for charging at hi voltage.Dont know why ,but when I had a not to good genny /I could tweak a 3 coil delco to put out 14.5 easily.After you have a good look at genny & the Field being not grounded as JOHN mentioned//Try cleaning the contacts in the delco & set them to the book settings.If no good still/--Measure how many amps your genny is putting out /using a fully charged batt. ofcourse.If genny proves to be good/The regulater may need changing.

[63 Duo]

Delco.jpg (442.87 KiB) Viewed 3806 times

Thank you again John , i have the service bulletin and i will try. After checking the field which i hope i ll try these days.
Where is it possible to have the field grounded. I did a physical check on my Generator and it seems ok. Did also the check when you measure the voltage before and after removing the F from the regulator and it is the same (high-8.5V) so it is supposed to be grounded in the generator right?
58flh: My three coil Delco Remy unit is a late 60s 6V Harley was using with some black plastic (or bakelite) circular screws for adjustment (the one one the right) It was NOS before 3000 miles so i believe, it s not too likely that it is at fault. I have a friend with a same regulator good working unit so i ll probably swap and check.
The other on the left is an unidentified Delco Remy 6V unit i used to compare.

[john HD]

so it is supposed to be grounded in the generator right?

Correct!

john

[63 Duo]

Thanks for the reply again John . Today i had some time and opened the generator. The only weak point i could see is where the field coils attach to the terminal screws figure 5E-1 of the service manual. There are two screws (22) but one bracket insulator. (21) to which terminal is it supposed to go? the one that the + brush connects or the other? or there are supposed to be two (21s). it might a problem with my generator assembly but it has worked ok for 3000 miles...
Or if it is not that , what kind of field grounding am i looking for?

[john HD]

63,

past performance is no indicator of what your generator is doing now.....

you need to verify the F terminal is not shorting out to the case of the generator. this is regardless of the parts that are in your generator now.

are you able to access a volt/ohm meter? at this point the visual inspection ends.....

john

[63 Duo]

Hi and thanks
Yes i do have those meters and i know how to make it run like a motor

[john HD]

Cool,

Once you determine the condition of the wires and insulators you mentioned you will need to check the condition of the coils themselves.

If it will motor without the F terminal grounded it is shorted internally.

john

[63 Duo]

Thank you John ,i ll check those on Monday.
Constantine

[63 Duo]

Disassembled Gen tonight, checked connections.
Made them again by the book, it runs as a motor without tightening the frame screws, does not run without the field grounded. When i tighten the screws, so far it does not run as a motor. Checked with the multimeter the coils and resistance is approx 3.6 Ohm (6 Volt system)
(to be continued)

[63 Duo]

Progress!!
Assemble genny correctly and tightened it , runs like a motor nicely, does not run without the F Grounded.
Put on bike , connected with Regulator (the correct one) and run the same high Volts , without capability of adjustment from Reg.
Took off Reg , saw some pitting or dirt on points, cleaned them with sharp blade, put on bike, now it can be adjusted. Did not have time for the whole correct procedure , nor am i sure that i can do it but i easily tweaked 7.5 V tops with lights on and 2500 or 3000 RPM.
Should i be happy that i am on the correct path?

PS on my Regulator (Top Right) are the two little black sprocket like knobs for adjusting the points gap?

[john HD]

Should i be happy that i am on the correct path?

Yes you should be happy. Sounds like you have the problem fixed.

I cannot comment on your regulator as I have not tried to adjust one like that. I think your assumption that the black knobs are for adjustment is correct.

john