How To Wire A Generator And Voltage Regulator (Step by Step Guide)

Wiring a generator and voltage regulator is very simple. In this guide, I’ll explain the process step-by-step to help you understand how you can wire your generator and voltage regulator.

Step-by-step Guide to Wiring A Generator and Voltage Regulator

A voltage regulator has a constant voltage output because it doesn’t fluctuate the voltage.

Some generators, such as 6-volt and 12-volt, need current at voltages.

Any slight fluctuation in voltage can easily alter electrical mechanisms, destroying the entire generator.

A voltage regulator works by taking the voltage from the battery, reducing it, and then sending it to the generator at a constant level.

For this process to work effectively, you have to connect three wires to the right regulator terminal.

Now that you have a general understanding of why you need to wire your generator and voltage regulator, let’s have a look at the step-by-step instructions:

1.  Check your generator

Before installing the voltage regulator, I always check if my generator is functioning.

I also check the condition of its battery because it’s an important part of the entire system.

Due to the wiring between the generator and regulator, the battery is at risk of getting corroded.

Not to worry, in case there is corrosion, remove it using fine sandpaper.

Before removing any battery wires from their connection points, ensure you label them so you can reconnect them correctly.

Note that you’ll have to polarise the generator before testing the voltage regulator.

To polarise it, connect the battery’s positive terminal to the generator’s armature.

Once you’ve done that, remove the entire battery.

Some manuals will instruct you to polarise the regulator, but this is impossible because regulators aren’t polarity sensitive.

In such scenarios, it simply means polarise the generator.

2. Pick the voltage regulator

It’s good to understand that there are various regulators, so you have to choose the suitable one for your generator.

Regulators have an indication of how much voltage they can control.

Therefore, the amount of voltage your generator gives should dictate the type of regulator you choose.

The most popular regulators range from 6-volts to 12-volts.

For easy identification, manufacturers have labeled the amperage and voltage on regulators.

A common mistake I realized people make is assuming that the higher the voltage on the regulator, the better it is for the battery and generator.

Picking the right regulator is crucial, especially if you’re going to mount it internally.

If the regulator fails, you can’t replace it, so you’ll have to reinstall the entire alternator, which can be quite expensive.

3. Welding the regulator mount to the tractor frame

Now that you’ve checked your generator and picked the regulator, it’s time to get to the actual work.

Start by welding the mount between the generator mount and coil housing.

There should be clear instructions in the regulator’s manual.

Some manuals recommend you position it vertically, while others require horizontal positioning.

The instructions will help you position the mount correctly.

4. Attaching the voltage regulator to the mount

To do this, screw the four corners of your regulator to the mount.

You’ll need a total of four screws, washers, and nuts.

Avoid tightening them as you screw the bolts because they will damage the regulator’s housing, especially if you’re using a plastic house.

5. Connecting the positive battery wire to the regulator

The next step is connecting the battery’s positive wire (red) to the regulator.

Connect it to the terminal labeled “B” or “BATT” on some regulators.

Ensure you connect the generator’s wire correctly.

The corresponding terminal on the generator wire is labeled “A” or “G”.

Connect the field coil wire to the regulator’s field terminal. It’s indicated as an “F” or “FIE”.

6. Polarising the generator through the regulator

To polarise the regulator, touch the end of the jumper wire to the regulator’s battery terminal.

Then touch the other wire to the field terminal.

Hold the wires on the terminals for a second, and release them.

Note that if you do this for more than one second, you’ll damage the regulator.

To answer a brief question, some people tend to ask: Does a voltage regulator work on a generator?

Yes, a voltage regulator simply regulates the output voltage of generators.

It does so by using a small portion of the voltage output, converting the AC voltage to DC, inversely proportional to the original generator’s output voltage.

So, in conclusion, to wire a generator and voltage regulator, follow these steps:

  1. Check your generator
  2. Pick the regulator
  3. Welding the regulator mount to the tractor frame
  4. Connecting the positive battery wire to the regulator
  5. Polarising the generator through the regulator

Hopefully, now you have a clear understanding of how to wire your generator and a regulator.

All the best!