Hj75 -intermittant charging problems

[dogbreath_48]

Having some electrical problems with my cruiser. Upon startup voltage is low, warning lights on and relays clicking in and out both passenger (charge?) and drivers (glow?) side. Once Revs build after a few seconds pass side relay clicks and voltage instantly increases, warning lights go out. Then whilst driving the problem occurs intermittantly. It's not charging more than it is. Preheat doesn't appear to be working. It will very rarely charge properly at idle. Doesn't appear to be associated with bumps in road or rpm (except at initial startup)

I'm assuming it's not an alt or batt problem as voltage is good when it's good - so something in the charge control circuit? I've had a quick loom at alt/batt and all connecions appear to be good. Voltage reg is <6mth old, bu it is my third in the past two years (previous two reg failures caused overcharging)

Any ideas? Where exactly is the charge relay?

Sorry for the brief question - posting from my phone...[/i]

[+dj_hansen+]

When you checked the connections did you pull them off, clean them up with some fine emery paper etc and put them all back together?

Just to eliminate poor connections causing high resistance.

Could also be the brush assembly in the alt itself as a similar thing happened with my old 4runner, gradually over time it got worse until all the lights came on driving home one night

Luckily all these old fangled diesels need is enough juice to hold the fuel cut solenoid open

[dogbreath_48]

I haven't had a chance to thoroughly check major connections but i've had them apart recently so I'm confident they're ok. Have never located the charge relay so obviously haven't checked that. Will check brushes tonight I did replace them fairly recently. Car hasn't seen mud in a while either...

My main concern is finding and identifying the charge relay.

Meant to be heading to wodonga Tuesday night so won't have a chance to seek professional help before then.

I understand the alternator needs to be excited to operate correctly. Is this the job of the charge relay? Is it possible to bypass the relay and 'hotwire' the alt as a temporary measure if this is the problem? Will need headlights

[Drift Technician]

I had the same after mine was rebuilt with new bushes.

Ended up seizing at 110km/h on the highway.

Replaced alternator with good second hand one and no problems now.

[Ruffy]

Hey Stu,
Sounds like you have a voltage regulator fault. Reg is on the LHS of the engine bay from memory. It's a little box, usually gold in color, possibly black if it's been replaced. Sometimes called a charge relay as it has contacts like a relay which open and close to vary charge as required. Will have two screws holding the 'lid' on it and a 6 pin plug with a short loom to it. They are generally a throw away item as the new ones are electronic instead of contacts.
Good luck..

PS.. missed you at wombat on the w/e...

[dogbreath_48]

Thanks dan. Mines internally reg'd, will try another new reg tonight. Three wires into to internal reg, two of which get 12v when engine is running which judging from a quick glance at the wiring diagrams seems to he correct. Ive had a bit of a dodgy setup where my intercooler fan/pump switches off the reg itself - this extra load could be what's caused multiple reg failures. Will have to find another solution for this.
If that doesn't work I'll have the alt rebuilt (has I tiny bit of lateral shaft play so I guess it could do with a freshen up anyway.

You missed me? Aww that's sweet